A production process of polyester yarn made of short fibers

Abstract

The application discloses a production process of polyester yarn made of short fibers, and relates to the technical field of polyester yarn production processes, and comprises the following steps: S1, fiber pretreatment: classifying and screening the short fibers, removing impurities and unqualified fibers; soaking the screened short fibers in a reagent combination mixed by 5% sodium hydroxide solution and 3% hydrogen peroxide solution at a ratio of 2:1; in the application, the layered and alternating mixing enables different types of short fibers to be more uniformly distributed and interwoven; helps to improve the strength of the yarn to above 950MPa; at the same time, the uniform fiber distribution also improves the air permeability of the yarn to above 600cm 3 / s; and the uniform structure and good fiber combination enable the dye to penetrate and adhere more uniformly during dyeing, with a dyeing uniformity of above 99% and a color fastness of grade 4-5; the high-quality yarn can be used to make textiles with more functionality and comfort, bringing more market opportunities for enterprises.

Description

Technical Field

[0001] This invention relates to the field of polyester yarn production technology, specifically a production process for making polyester yarn from short fibers. Background Technology

[0002] Polyester yarn usually refers to the cotton yarn used to produce polyester. Polyester is a type of fiber made from polymers through spinning. Currently, it is mainly produced from polyethylene terephthalate (PET), and is commonly known as polyester in my country, or simply "PET" fiber. "Yarn" is a slender object with a certain strength and linear density, formed by arranging many short fibers or filaments in a nearly parallel state and twisting them axially; while "thread" is a ply made by twisting two or more single yarns together. Polyester staple fiber is a short fiber ranging from a few centimeters to over ten centimeters in length. It is obtained by spinning polyester (polyethylene terephthalate, polymerized from PTA and MEG) into filaments and then cutting them.

[0003] The existing production process for making polyester yarn from short fibers has several significant problems, especially in the blending process: First, the determination of the blending ratio lacks scientific rigor and accuracy, leading to unstable yarn performance and failing to fully utilize the advantages of different types of short fibers. Second, the blending method is mostly a simple random mixing, without employing an orderly, alternating layering approach, resulting in uneven fiber distribution, inconsistent gap sizes, and poor yarn strength, abrasion resistance, and pilling resistance. Simultaneously, the classification of short fiber length and fineness is not precise enough, and the layup sequence is chaotic, leading to loose fiber bonding, affecting yarn quality, and making it difficult to untangle the fibers. The uneven fiber laying process increases the defect rate; the improper selection of finishing agents, often non-environmentally friendly ones, is also a problem, resulting in poor treatment effects and failing to effectively improve the color fastness, antibacterial properties, and softness of the yarn. In summary, the existing production process for polyester yarn from short fibers has many defects in the blending and post-treatment stages, making it impossible to produce high-quality polyester yarn with high strength, high breathability, high dyeing uniformity, high color fastness, and good softness, which is insufficient to meet the market demand for high-end textiles. An innovative and optimized production process is urgently needed to solve these problems.

[0004] In view of this, a production process for making polyester yarn from short fibers is provided to overcome the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a production process for making polyester yarn from short fibers, so as to solve the problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the present invention provides a production process for making polyester yarn from short fibers, comprising the following steps:

[0007] S1. Fiber pretreatment: The short fibers are sorted and screened to remove impurities and unqualified fibers; the screened short fibers are soaked in a reagent combination of 5% sodium hydroxide solution and 3% hydrogen peroxide solution in a 2:1 ratio for 30 minutes.

[0008] S2, Blending process:

[0009] S2.1 Blending ratio: set at 40% type A short fiber and 60% type B short fiber;

[0010] S2.2 Humidification: Before blending, the two types of short fibers are pre-humidified to control the moisture content to 8%.

[0011] S2.3 Layered Alternating Mixing: The blending method is to first evenly lay a layer of type A short fibers, then lay a layer of type B short fibers, and so on alternately;

[0012] S2.4 Refined Blending: Type A and Type B short fibers are classified by length and fineness: Type A short fibers are divided into three categories according to length: short, medium, and long, and also into three grades of fineness: fine, medium, and coarse; Type B short fibers are classified in the same way; when laying the first layer of Type A short fibers, they are arranged in order from fine to coarse and from short to long; then the first layer of Type B short fibers is laid, also in order from fine to coarse and from short to long, but at a 45-degree angle to the arrangement direction of Type A short fibers;

[0013] S2.5 Laying: Use automatic lay-up equipment; and use ultrasonic-assisted blending, with the frequency set at 30kHz and the action time at 20 minutes;

[0014] S3. Spinning preparation: Use spinning auxiliaries containing 5% silicone oil, 3% antistatic agent and 2% softener;

[0015] S4. Spinning process: In high-speed rotating airflow spinning technology, the airflow speed is set to 300m / s and the spinning twist is 1000 twists / m.

[0016] S5. Post-processing:

[0017] S5.1 Temperature control: The heat setting temperature is controlled at 180℃, the stretching ratio is 1.5 times, and the duration is 10 minutes;

[0018] S5.2 Introduce environmentally friendly finishing agents, select tea tree extract and aloe vera extract at a concentration of 8%, soak for 20 minutes, control the pH value of the soaking solution between 5.5 and 6.5, and control and adjust the temperature of the soaking solution between 35℃ and 45℃.

[0019] S5.3, Ultraviolet irradiation is used, with an intensity of 100W / m. 2 Irradiation time: 15 minutes;

[0020] S5.4. Low-temperature vacuum drying is adopted, with the vacuum degree controlled at -0.08MPa, the temperature at 50℃, and the drying time at 30 minutes.

[0021] Furthermore, in S1, the solution temperature is maintained at 40°C during the soaking process and the mixture is continuously stirred; the fiber surface is treated with low-temperature plasma technology, and the discharge power is controlled at 100W, the treatment time is 10 minutes, and the gas flow rate is 10L / min; then, microwave radiation pretreatment is performed, with a microwave frequency of 2450MHz and a radiation time of 5 minutes, and a circulating water cooling system is used during the radiation process.

[0022] Furthermore, in S2.5, the uniformity of fiber laying is monitored in real time. Through multiple high-definition cameras and image recognition technology installed on the automatic layup equipment, the operating parameters of the nozzle are automatically adjusted immediately once an uneven area is detected.

[0023] Furthermore, in S2, the blending room maintains a constant temperature and humidity environment, with the temperature controlled at 25℃±2℃ and the relative humidity controlled at 60%±5%.

[0024] Furthermore, in S3, when preparing the spinning auxiliaries, the silicone oil and antistatic agent are first thoroughly mixed, and then the softener is added and stirred evenly; the electrostatic field strength is controlled at 50kV / m, and the action time is 15 minutes.

[0025] Furthermore, in S4, a high-precision tension sensor is used to monitor the spinning tension in real time. The sensor is installed at the spinning spindle, the guide wheel or guide rod, or in front of the yarn winding device.

[0026] Furthermore, in S5.2, a circulating stirring device is used during the soaking process.

[0027] Furthermore, S5.2 introduces ultrasonic-assisted penetration technology, with the ultrasonic frequency set at 40kHz and the action time at 10 minutes.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] The layered, alternating blending allows for a more even distribution and interweaving of different types of short fibers. During the laying process, the fibers are arranged in a specific order and manner, ensuring uniform spacing between fibers and resulting in a more stable and uniform distribution in the yarn structure. This uniform structure helps improve the yarn's strength, enabling it to withstand greater tensile forces, reaching over 950 MPa. Simultaneously, the uniform fiber distribution also improves the yarn's air permeability, increasing it to 600 cm². 3The yarn has a uniform structure and good fiber bonding, which allows the dye to penetrate and adhere more evenly during dyeing, with a dyeing uniformity of over 99% and a color fastness of 4-5. The high-quality yarn can be used to make more functional and comfortable textiles, such as high-performance sportswear and medical protective equipment, which broadens the application range of the products and brings more market opportunities to enterprises.

[0030] By installing high-precision tension sensors at multiple points, including the spinning spindle, guide rollers or guide rods, and before the yarn winding device, tension changes during the spinning process can be comprehensively and accurately monitored. When the tension exceeds a set threshold, the intelligent control system can quickly and accurately adjust automatically within a short time, ensuring stable yarn tension during spinning. Stable tension helps the yarn fibers to arrange themselves in an orderly and tight manner, thereby enhancing yarn strength to over 900 MPa, reducing the coefficient of variation of breaking elongation, and significantly reducing the defect rate. At the same time, stable tension can also reduce defects in the yarn structure, improve yarn uniformity, and thus enhance air permeability, dyeing uniformity, and color fastness, enabling the yarn's performance indicators to meet the requirements of the high-end market and improving product competitiveness.

[0031] Environmentally friendly finishing agents such as tea tree extract and aloe vera extract are selected, and parameters such as their concentration, pH value, temperature, and treatment time are controlled. These natural extracts can form a protective film on the yarn surface, enhancing the yarn's color fastness to grade 4-5, making it less prone to fading during use and washing. Simultaneously, it enhances antibacterial properties, increasing the inhibition rate to over 95%, and improves softness by over 30%, further optimizing yarn performance to meet the stringent demands of the high-end market for high-quality yarn and enhancing the product's competitiveness in the market. The use of environmentally friendly finishing agents and low-temperature vacuum drying technology reduces environmental pollution, aligns with current societal requirements for sustainable development, and enhances the company's social image. Attached Figure Description

[0032] Figure 1 This is a flowchart of a production process for making polyester yarn from short fibers according to 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 only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Please see Figure 1 The present invention provides a technical solution:

[0035] See Figure 1 As shown, a production process for making polyester yarn from short fibers includes the following steps:

[0036] S1. Fiber Pretreatment: Short fibers are sorted and screened to remove impurities and unqualified fibers; the screened short fibers are immersed in a reagent combination of 5% sodium hydroxide solution and 3% hydrogen peroxide solution in a 2:1 ratio for 30 minutes; the solution temperature is maintained at 40℃ during immersion and the solution is stirred continuously; the fiber surface is treated with low-temperature plasma technology, with the discharge power controlled at 100W, the treatment time at 10 minutes, and the gas flow rate at 10L / min; then microwave radiation pretreatment is performed, with a microwave frequency of 2450MHz and a radiation time of 5 minutes. A circulating water cooling system is used during the radiation process to prevent the fibers from overheating.

[0037] Specific implementation method:

[0038] Fiber sorting and screening: A vibrating screen can be used to remove impurities and unqualified fibers by setting appropriate screen aperture and vibration frequency according to parameters such as fiber length and fineness.

[0039] Soaking treatment: carried out in a soaking tank equipped with heating and stirring devices; first, prepare a mixture of 5% sodium hydroxide solution and 3% hydrogen peroxide solution according to the ratio, put the screened short fibers into the soaking tank, maintain the solution temperature at 40°C by temperature sensor and heating element, and stir continuously using electric stirrer.

[0040] Low-temperature plasma treatment: A specialized low-temperature plasma treatment device is used, with the discharge power set at 100W, the treatment time at 10 minutes, and the gas flow rate controlled at 10L / min.

[0041] Microwave radiation pretreatment: Use industrial microwave radiation equipment, set the frequency to 2450MHz, the radiation time to 5 minutes, and start the circulating water cooling system at the same time.

[0042] Example 1 of fiber pretreatment:

[0043] Fiber sorting and screening: Using a multi-layer screen with an aperture of 0.5-5 mm and a vibration frequency of 500 times / minute, 97% of impurities and unqualified fibers are successfully removed;

[0044] Soaking treatment: The stirring speed is 80 rpm, and the cleanliness of the fibers is improved by 90% after soaking;

[0045] Low-temperature plasma treatment: The surface roughness of the fiber is reduced and its hydrophilicity is improved after treatment;

[0046] Microwave radiation pretreatment: improves fiber crystallinity and enhances subsequent spinning performance;

[0047] The final polyester yarn exhibits excellent performance in terms of strength, abrasion resistance, and anti-pilling properties; compared with traditional pretreatment processes, the strength is increased by 18%, the abrasion resistance is increased by 15%, and the anti-pilling grade is improved from level 2 to level 3.5.

[0048] Example 2 of fiber pretreatment:

[0049] Fiber sorting and screening: An intelligent optical detection system is introduced to assist in screening, achieving an impurity removal rate of 98%;

[0050] Soaking treatment: Utilizing more precise temperature control and stirring devices results in better soaking effects;

[0051] Low-temperature plasma treatment: Optimizes gas composition and further improves fiber surface properties;

[0052] Microwave radiation pretreatment: Adjusting the microwave radiation power to make the internal structure of the fiber more uniform;

[0053] The resulting polyester yarn has 22% higher strength, 20% higher abrasion resistance, and a pilling resistance rating of 4 compared to traditional processes.

[0054] Comparative Example 1 of fiber pretreatment:

[0055] With only simple manual sorting and screening, the impurity removal rate is approximately 70%.

[0056] It was not subjected to immersion, low-temperature plasma, or microwave radiation treatment;

[0057] Ultimately, the properties of the polyester yarn are similar to those of traditional processes, with no significant improvement.

[0058] Comparative Example 2 of fiber pretreatment:

[0059] Fiber sorting and soaking treatment were carried out, but the soaking temperature was 30℃ and the stirring speed was 50 rpm;

[0060] No low-temperature plasma and microwave radiation treatment was performed;

[0061] The resulting polyester yarn has an 8% higher strength, a 5% higher abrasion resistance, and a pilling resistance rating of 2.5 compared to traditional processes.

[0062] Comparative Example 3 of fiber pretreatment:

[0063] The fibers were sorted, soaked, and treated with low-temperature plasma. The discharge power of the low-temperature plasma treatment was 80W, and the treatment time was 5 minutes.

[0064] Microwave radiation preprocessing omitted;

[0065] The resulting polyester yarn has a 12% higher strength, an 8% higher abrasion resistance, and a pilling resistance rating of 3 compared to traditional processes.

[0066] Based on the above examples and comparative data of fiber pretreatment, the following conclusions can be drawn:

[0067] The optimal method includes: mixing 5% sodium hydroxide solution and 3% hydrogen peroxide solution in a 2:1 ratio, soaking temperature of 40℃, stirring speed of 80 rpm or more, low-temperature plasma discharge power of 100W, treatment time of 10 minutes, gas flow rate of 10L / min, and 2450MHz microwave radiation for 5 minutes.

[0068] The effects of fiber pretreatment are:

[0069] It significantly improves the strength of polyester yarn, enabling it to withstand greater tension and abrasion, making it suitable for producing high-strength textiles such as industrial fabrics; it significantly enhances abrasion resistance, extends the service life of textiles, and reduces replacement costs; it effectively improves anti-pilling properties, enhances the appearance quality and comfort of products, and meets consumers' demand for high-quality textiles; it optimizes the surface and internal structure of fibers, providing a good foundation for subsequent blending, spinning, and post-processing, and improving the efficiency of the entire production process and the stability of product quality.

[0070] S2, Blending process:

[0071] S2.1 Blending ratio: set at 40% type A short fiber and 60% type B short fiber;

[0072] S2.2 Humidification: Before blending, the two types of short fibers are pre-humidified to control the moisture content to 8%.

[0073] S2.3 Layered Alternating Mixing: The blending method is to first evenly lay a layer of type A short fibers, then lay a layer of type B short fibers, and so on alternately;

[0074] S2.4 Refined Blending: Type A and Type B short fibers are classified by length and fineness: Type A short fibers are divided into three categories according to length: short, medium, and long, and also into three grades of fineness: fine, medium, and coarse; Type B short fibers are classified in the same way; when laying the first layer of Type A short fibers, they are arranged in order from fine to coarse and from short to long; then the first layer of Type B short fibers is laid, also in order from fine to coarse and from short to long, but at a 45-degree angle to the arrangement direction of Type A short fibers;

[0075] S2.5 Laying: Automated lay-up equipment is used; the uniformity of fiber laying is monitored in real time. Through multiple high-definition cameras and image recognition technology installed on the automated lay-up equipment, the working parameters of the nozzles are automatically adjusted immediately once an uneven area is detected; ultrasonic-assisted blending is used, with the frequency set at 30kHz and the action time at 20 minutes; a constant temperature and humidity environment is maintained in the blending chamber, with the temperature controlled at 25℃±2℃ and the relative humidity controlled at 60%±5%, to reduce the generation of static electricity and moisture absorption differences in the fibers during the laying process, further ensuring the uniformity and stability of the blend;

[0076] Example illustration:

[0077] Example 1 of the blending process:

[0078] Using a high-precision measuring device, 40 kg of type A short fiber and 60 kg of type B short fiber were accurately weighed, and the actual blending ratio was 40.5% type A and 59.5% type B.

[0079] The short fibers were pre-humidified using a spray humidifier to control the moisture content to 8.5%.

[0080] Using advanced automatic layup equipment, a layer of type A short fiber is laid evenly first, followed by a layer of type B short fiber, and the process is repeated to achieve a uniform laying effect.

[0081] Using professional fiber measuring equipment, type A and type B short fibers are classified. When laying the first layer of type A short fibers, the order of fine to coarse and short to long is strictly followed. When laying the first layer of type B short fibers, the direction of arrangement of type A short fibers is 45 degrees.

[0082] The automatic lay-up equipment is equipped with eight high-definition cameras and an advanced image recognition system to monitor the fiber lay-up uniformity in real time. Once an uneven area is detected, the nozzle operating parameters are automatically adjusted within 0.1 seconds. Ultrasonic waves assist in blending at a frequency of 30kHz for 20 minutes, and the temperature in the blending chamber is stabilized at 23℃ with a relative humidity of 58%.

[0083] The final polyester yarn exhibits excellent performance in terms of strength, abrasion resistance, and anti-pilling properties; compared with polyester yarn produced by conventional blending processes, its strength is increased by 20%, abrasion resistance is improved by 18%, and anti-pilling properties are improved from level 3 to level 4.

[0084] Example 2 of the blending process:

[0085] With the help of an automated fiber conveying system, the fibers are conveyed in a ratio of 40% type A short fibers and 60% type B short fibers, with the actual ratio being 39.2% type A and 60.8% type B.

[0086] Steam pre-humidification was used to bring the moisture content of the short fibers to 7.8%.

[0087] Using intelligent automatic layering equipment, the alternating layering process is smooth and without obvious defects;

[0088] High-precision laser measurement technology is used to classify and lay the fibers in an accurate and error-free sequence;

[0089] The image recognition technology and nozzle adjustment system have a response time of 0.08 seconds. The ultrasonic-assisted blending effect is significant. The temperature in the blending chamber is maintained at 27℃ and the relative humidity is 62%.

[0090] The produced polyester yarn has a 22% increase in strength, a 20% increase in abrasion resistance, and a pilling resistance rating of 4.5.

[0091] Comparative Example 1 of the blending process:

[0092] The blending ratio is 20% type A short fiber and 80% type B short fiber;

[0093] No pre-humidification treatment is performed;

[0094] Two short fibers are randomly mixed without alternating layering.

[0095] Short fibers are not classified by length and fineness and are laid out arbitrarily;

[0096] The fiber laying uniformity is observed manually. There is no automatic nozzle adjustment function. Ultrasonic-assisted blending is not used. The blending room temperature is 30℃ and the relative humidity is 45%.

[0097] The produced polyester yarn was significantly inferior to the example in terms of strength, abrasion resistance, and anti-pilling performance. Its strength was only 70% of that of Example 1 in the blending process, its abrasion resistance was reduced by 30%, and its anti-pilling performance was level 2.

[0098] Comparative Example 2 of the blending process:

[0099] The blending ratio is 50% type A short fiber and 50% type B short fiber;

[0100] Pre-humidification treatment, but the moisture content is controlled at 5%;

[0101] The layers are mixed alternately but the application is uneven.

[0102] The classification of short fibers was inaccurate, and the laying sequence was incorrect.

[0103] Image recognition is available, but the nozzle adjustment is not timely. The ultrasonic frequency is 20kHz, the blending room temperature is 20℃, and the relative humidity is 50%.

[0104] The polyester yarn produced in this comparative example also has inferior performance compared to the example. Its strength is 85% of that of Example 1 in the blending process, its abrasion resistance is reduced by 20%, and its anti-pilling performance is level 3.

[0105] Based on the above examples and comparative data of the blending process, the following conclusions can be drawn:

[0106] The optimal methods include: accurate blending ratio (40% for type A, 60% for type B), appropriate pre-humidification treatment (moisture content of about 8%), layered and alternating blending method, precise fiber classification and laying sequence, efficient automatic lay-up and monitoring and adjustment equipment, suitable ultrasonic-assisted blending, and a stable constant temperature and humidity environment.

[0107] The effect is:

[0108] It significantly improves the strength of polyester yarn, making it more durable and less prone to breakage in subsequent textile applications; enhances abrasion resistance, extends product lifespan, and reduces replacement costs; improves anti-pilling and anti-fuzzing properties, enhancing product appearance quality and user comfort to meet consumers' high-quality demands; and ensures the uniformity and stability of the blend, improving product quality consistency and reducing defect rates.

[0109] S3. Spinning preparation: Use spinning auxiliaries containing 5% silicone oil, 3% antistatic agent and 2% softener; when preparing the spinning auxiliaries, first mix the silicone oil and antistatic agent thoroughly, then add the softener and stir evenly; control the electrostatic field strength at 50kV / m and the action time at 15 minutes.

[0110] Example 1 of spinning preparation:

[0111] Preparation of spinning auxiliaries: Accurately weigh 50 grams of silicone oil, 30 grams of antistatic agent and 20 grams of softener; first, stir the silicone oil and antistatic agent in a mixer at 300 rpm for 10 minutes to mix them thoroughly; then add the softener and continue stirring for 5 minutes until the mixture is uniform.

[0112] Electrostatic field treatment: In a specialized electrostatic treatment device, the electrostatic field strength is set to 50kV / m, and the fiber is subjected to the electric field for 15 minutes.

[0113] After this spinning preparation process, the produced polyester yarn exhibits excellent softness, antistatic properties, and smoothness. Compared with conventional spinning preparation processes, the softness is increased by 20%, the antistatic properties are reduced from a surface resistance of 10^10 ohms to 10^8 ohms, and the smoothness is also significantly improved.

[0114] Example 2 of spinning preparation:

[0115] Preparation of spinning auxiliaries: Using high-precision measuring instruments, weigh 55 grams of silicone oil, 25 grams of antistatic agent and 20 grams of softener; first, stir the silicone oil and antistatic agent in a sealed mixing container at a speed of 400 rpm for 8 minutes, and after mixing thoroughly, add the softener and stir for another 6 minutes to ensure uniformity;

[0116] Electrostatic field treatment: Optimize the parameters of the electrostatic treatment equipment to stabilize the electrostatic field strength at 52kV / m and strictly control the fiber treatment time to 15 minutes;

[0117] The resulting polyester yarn exhibited a 25% increase in softness, achieved an antistatic property with a surface resistance of 10^7 ohms, and significantly enhanced smoothness.

[0118] Comparative Example 1 of Spinning Preparation:

[0119] Spinning auxiliary agent formulation: Only 3% silicone oil, 2% antistatic agent and 1% softener were used, and the mixture was not thoroughly stirred;

[0120] Electrostatic field treatment: electrostatic field strength is 30kV / m, and the treatment time is 10 minutes;

[0121] The polyester yarn produced in this comparative example had poor softness, antistatic properties, and smoothness. Compared with Example 1, which was used for spinning preparation, the softness was reduced by 30%, the antistatic property was a surface resistance of 10^11 ohms, and the smoothness was also significantly insufficient.

[0122] Comparative Example 2 of Spinning Preparation:

[0123] Spinning auxiliary agent formulation: 8% silicone oil, 1% antistatic agent and 1% softener were used, but the stirring order was incorrect;

[0124] Electrostatic field treatment: The electrostatic field strength is unstable, fluctuating between 40-60kV / m, and the treatment time is 18 minutes;

[0125] The produced polyester yarn has uneven properties, with excessive softness but insufficient antistatic properties, and its smoothness is not as good as the example of spinning preparation.

[0126] Based on the above examples and comparative data on yarn preparation, the following conclusions can be drawn:

[0127] The optimal composition includes 5% silicone oil, 3% antistatic agent and 2% softener; the method is to first mix the silicone oil and antistatic agent thoroughly, then add the softener and stir evenly, while controlling the electrostatic field strength at 50kV / m and the action time at 15 minutes.

[0128] The effect is:

[0129] It significantly improves the softness of polyester yarn, giving it a better feel and comfort in subsequent textile processing and use, making it suitable for making underwear and other garments; it effectively enhances antistatic properties, reducing static electricity accumulation in the yarn during processing and use, improving production efficiency and product quality, and avoiding the adverse effects of static electricity on products; it improves the smoothness of the yarn, reduces the coefficient of friction, which is beneficial to subsequent textile processes, reduces the occurrence of breaks and defects, and improves the continuity and stability of production.

[0130] S4. Spinning Process: In high-speed rotating airflow spinning technology, the airflow speed is set to 300m / s, and the spinning twist is 1000 twists / m. Real-time monitoring of spinning tension is achieved using a high-precision tension sensor, which is installed at the spinning spindle, the guide wheel or guide rod, and before the yarn winding device to ensure accurate tension measurement. When the tension exceeds the set threshold, the intelligent control system automatically adjusts it within 0.5 seconds. The algorithm of the intelligent control system should be optimized to achieve fast and accurate adjustment.

[0131] Example 1 of the spinning process:

[0132] Airflow velocity: A precise airflow control device is used to stably set the airflow velocity to 300m / s;

[0133] Spinning twist: The spinning twist is precisely controlled to 1000 twists / m using advanced spinning equipment;

[0134] Tension monitoring and adjustment: High-precision tension sensors are installed at the spinning spindle, the yarn guide wheel and the yarn guide rod, and in front of the yarn winding device; when the tension exceeds the set threshold (e.g., 10N), the intelligent control system makes a rapid adjustment within 0.5 seconds, with an adjustment accuracy of ±0.5N;

[0135] The polyester yarn produced through this spinning process has good yarn strength uniformity and a low coefficient of variation of breaking elongation of 5%. Compared with traditional spinning processes, the quality stability of the yarn is greatly improved and the defect rate is reduced by 20%.

[0136] Example 2 of the spinning process:

[0137] Airflow velocity: Further optimize airflow control to keep airflow velocity fluctuations within ±5m / s and average velocity at 300m / s;

[0138] Spinning twist: Using a more precise spinning twist control device, the spinning twist deviation is controlled within ±5 twists / m, and the actual average twist is 1000 twists / m;

[0139] Tension monitoring and adjustment: The number and accuracy of tension sensors have been increased, the tension threshold has been set to 8N, the adjustment time of the intelligent control system has been shortened to 0.4 seconds, and the adjustment accuracy has reached ±0.3N;

[0140] The resulting polyester yarn exhibits excellent strength uniformity, with a coefficient of variation of only 3% for elongation at break. The product quality is significantly superior to that of Example 1 in the spinning process, with the defect rate further reduced to 5%.

[0141] Comparative Example 1 of the spinning process:

[0142] Airflow velocity: The airflow velocity is unstable, fluctuating between 250-350 m / s; Spinning twist: The spinning twist is not accurately controlled, varying between 800-1200 twists / m; Tension monitoring and adjustment: Tension sensors are only installed at the spinning spindle, the tension threshold is set inappropriately (e.g., 15 N), the adjustment time is as long as 2 seconds, and the adjustment accuracy is ±2 N.

[0143] Polyester yarn produced under these conditions has poor strength uniformity, a breaking elongation coefficient variation rate as high as 15%, and a defect rate as high as 30%.

[0144] Comparative Example 2 of the spinning process:

[0145] Airflow velocity: The airflow velocity is set to 280 m / s; Spinning twist: The spinning twist is 800 twists / m; Tension monitoring and adjustment: A low-precision tension sensor is installed at the yarn guide wheel, with a tension threshold of 12 N, an adjustment time of 1 second, and an adjustment accuracy of ±1.5 N; The quality of the polyester yarn produced is significantly lower than that of the example, with a breaking elongation coefficient of variation of 10% and a defect rate of 20%;

[0146] Based on the above examples and comparative data of the spinning process, the following conclusions can be drawn:

[0147] The optimal methods include: a stable airflow speed of 300m / s, a precise spinning twist of 1000 twists / m, comprehensive and high-precision tension monitoring (sensors installed at the spinning spindle, guide wheel or guide rod, and in front of the yarn winding device), and a fast and accurate (within 0.5 seconds, accuracy ±0.5N) intelligent tension adjustment control system.

[0148] The effect is:

[0149] Significantly improves the quality stability of polyester yarn, ensuring high consistency in strength, elongation, and other aspects, meeting the stringent requirements of high-end textiles for yarn quality; greatly reduces the defect rate, minimizes raw material waste, and improves production efficiency and economic benefits; precise tension control helps reduce yarn breakage during spinning, improving production continuity and efficiency; stable and suitable airflow velocity and spinning twist can optimize the structure and performance of the yarn, giving it better physical properties and textile processing performance.

[0150] S5. Post-processing:

[0151] S5.1 Temperature control: The heat setting temperature is controlled at 180℃, the stretching ratio is 1.5 times, and the duration is 10 minutes;

[0152] S5.2 Introducing environmentally friendly finishing agents, using tea tree extract and aloe vera extract at a concentration of 8%, soaking for 20 minutes, controlling the pH value of the soaking solution between 5.5 and 6.5, and controlling and adjusting the temperature of the soaking solution between 35℃ and 45℃; using a circulating stirring device during the soaking process to ensure full contact between the yarn and the finishing agent; also introducing ultrasonic-assisted penetration technology, with the ultrasonic frequency set at 40kHz and the action time at 10 minutes, to accelerate the penetration and uniform distribution of the finishing agent inside the yarn;

[0153] S5.3, Ultraviolet irradiation is used, with an intensity of 100W / m. 2 Irradiation time: 15 minutes;

[0154] S5.4. Low-temperature vacuum drying is adopted, with the vacuum degree controlled at -0.08MPa, the temperature at 50℃, and the drying time at 30 minutes.

[0155] Example 1 of post-processing:

[0156] During the heat setting process, a precise temperature control device was used to stably maintain the temperature at 180℃, the stretching ratio was accurately set to 1.5 times, and the duration was strictly controlled to 10 minutes. High-quality tea tree extract and aloe vera extract were selected as environmentally friendly finishing agents, with a concentration accurately prepared at 8%. The pH value of the soaking solution was controlled at 6.0, and the temperature was maintained at 40℃. The circulating stirring device operated at a speed of 80 rpm, the ultrasonic frequency was 40 kHz, and the action time was 10 minutes. The ultraviolet irradiation intensity was stabilized at 100 W / m². 2 The irradiation time is precisely controlled to be 15 minutes; during low-temperature vacuum drying, the vacuum degree is precisely controlled at -0.08MPa, the temperature is maintained at 50℃, and the drying time is 30 minutes.

[0157] After this processing step, the resulting polyester yarn exhibits excellent color fastness, antibacterial properties, and softness. Compared with conventional post-processing, the color fastness is improved by 2 grades, the antibacterial property achieves an inhibition rate of over 95% against common bacteria, and the softness is improved by 30%.

[0158] Example 2 of post-processing:

[0159] The heat setting temperature control accuracy reaches ±1℃, the stretching ratio deviation is less than 0.1 times, and the duration error does not exceed 1 minute;

[0160] Strictly control the quality and concentration of the finishing agent; the pH value of the soaking solution is 5.8, and the temperature is 38℃.

[0161] The circulation stirring speed is increased to 100 rpm, resulting in better ultrasonic effects;

[0162] The intensity of ultraviolet radiation fluctuates within ±5W / m 2 Within this range, the irradiation time is precisely controlled; the vacuum level is even more precisely controlled, the temperature fluctuation is less than ±2℃, and the drying time is accurate.

[0163] The resulting polyester yarn has a color fastness that is further improved to level 4-5, an antibacterial inhibition rate of 98% against common bacteria, and a softness that is improved by 35%.

[0164] Post-processing Comparative Example 1:

[0165] The heat setting temperature is 160℃, the stretching ratio is 1.2 times, and the duration is 8 minutes;

[0166] The finishing agent concentration was 5%, the soaking solution pH was 5.0, the temperature was 30℃, the circulation stirring speed was 50 rpm, and there was no ultrasonic assistance.

[0167] The intensity of ultraviolet radiation is 80W / m 2 The irradiation time was 10 minutes; the vacuum degree was -0.06 MPa; the temperature was 40℃; and the drying time was 20 minutes.

[0168] The polyester yarn produced in this comparative ratio was significantly worse in terms of color fastness, antibacterial properties, and softness. The color fastness was grade 2-3, the antibacterial inhibition rate was about 70%, and the softness was improved by less than 10%.

[0169] Post-processing Comparative Example 2:

[0170] The heat setting temperature is 200℃, the stretching ratio is 2.0 times, and the duration is 12 minutes;

[0171] The finishing agent concentration was 10%, the soaking solution pH was 7.0, the temperature was 50℃, the circulating stirring speed was 120 rpm, and the ultrasonic frequency was too high.

[0172] The intensity of ultraviolet radiation is 120W / m 2 The irradiation time was 20 minutes; the vacuum degree was -0.1 MPa; the temperature was 60℃; and the drying time was 40 minutes.

[0173] In this comparative example, the performance of the polyester yarn is uneven. Some properties are improved, but the overall quality is not as good as the example, and there is fiber damage caused by over-processing.

[0174] Based on the above post-processing examples and comparative data, the following conclusions can be drawn:

[0175] The optimal method includes: heat setting temperature of 180℃, stretching ratio of 1.5 times, duration of 10 minutes; finishing agent concentration of 8%, soaking solution pH of 5.5-6.5, temperature of 35-45℃, circulation stirring and 40kHz ultrasonic assistance for 10 minutes;

[0176] UV radiation intensity 100W / m 2 Irradiation time: 15 minutes; Low-temperature vacuum drying: vacuum degree: -0.08MPa, temperature: 50℃, drying time: 30 minutes;

[0177] The effect is:

[0178] Significantly improves the colorfastness of polyester yarn, making it less prone to fading during use and washing, maintaining vibrant colors, and enhancing the appearance quality and durability of products; enhances antibacterial properties, giving textiles made from polyester yarn better hygiene and health functions, meeting consumers' health needs; effectively improves softness, increasing the comfort and feel of textiles, and improving the market competitiveness of products; optimized post-processing ensures the stability and consistency of yarn performance, improving production efficiency and product qualification rate.

[0179] Summarize:

[0180] This production process comprises five steps: fiber pretreatment, blending, spinning preparation, spinning process, and post-treatment. Fiber pretreatment optimizes fibers through sorting, screening, and soaking in specific reagents. The blending process improves blending effects by setting proportions, pre-humidifying, and alternating layered blending. Spinning preparation determines auxiliary agent components and electrostatic field treatment parameters. The spinning process controls airflow speed, spinning twist, and tension monitoring and adjustment. Post-treatment includes heat setting and treatment with environmentally friendly finishing agents. Each step includes examples, comparative examples, and optimal method conclusions, all demonstrating significant effects.

[0181] Layered alternating mixing method in the blending process:

[0182]

[0183] The layered, alternating blending allows for a more even distribution and interweaving of different types of short fibers. During the laying process, the fibers are arranged in a specific order and manner, ensuring uniform spacing between fibers and resulting in a more stable and uniform distribution in the yarn structure. This uniform structure helps improve the yarn's strength, enabling it to withstand greater tensile forces, reaching over 950 MPa. Simultaneously, the uniform fiber distribution also improves the yarn's air permeability, increasing it to 600 cm². 3The yarn has a uniform structure and good fiber bonding, which allows the dye to penetrate and adhere more evenly during dyeing, with a dyeing uniformity of over 99% and a color fastness of 4-5. The high-quality yarn can be used to make more functional and comfortable textiles, such as high-performance sportswear and medical protective equipment, which broadens the application range of the products and brings more market opportunities to enterprises.

[0184] Real-time tension monitoring and automatic adjustment during the spinning process:

[0185]

[0186] By installing high-precision tension sensors at multiple points, including the spinning spindle, guide rollers or guide rods, and before the yarn winding device, tension changes during the spinning process can be monitored comprehensively and accurately. When the tension exceeds a set threshold, the intelligent control system can quickly and accurately adjust automatically within a short time (within 0.5 seconds), ensuring stable yarn tension during spinning. Stable tension helps the yarn fibers to arrange themselves in an orderly and tight manner, thereby enhancing yarn strength to over 900 MPa, reducing the coefficient of variation of breaking elongation, and significantly reducing the defect rate. At the same time, stable tension can also reduce defects in the yarn structure, improve yarn uniformity, and thus enhance air permeability, dyeing uniformity, and color fastness, enabling the yarn's performance indicators to meet the requirements of the high-end market and improving product competitiveness.

[0187] Selection of environmentally friendly finishing agents in post-treatment steps:

[0188]

[0189] Environmentally friendly finishing agents such as tea tree extract and aloe vera extract are selected, and parameters such as their concentration, pH value, temperature, and treatment time are controlled. These natural extracts can form a protective film on the yarn surface, enhancing the yarn's color fastness to grade 4-5, making it less prone to fading during use and washing. Simultaneously, it enhances antibacterial properties, increasing the inhibition rate to over 95%, and improves softness by over 30%, further optimizing yarn performance to meet the stringent demands of the high-end market for high-quality yarn and enhancing the product's competitiveness in the market. The use of environmentally friendly finishing agents and low-temperature vacuum drying technology reduces environmental pollution, aligns with current societal requirements for sustainable development, and enhances the company's social image.

Claims

1. A process for the production of staple fibre made polyester yarn, characterized by, Includes the following steps: S1. Fiber pretreatment: Short fibers are sorted and screened to remove impurities and unqualified fibers; The screened short fibers were immersed in a reagent mixture of 5% sodium hydroxide solution and 3% hydrogen peroxide solution in a 2:1 ratio for 30 minutes, maintaining the solution temperature at 40°C and stirring continuously. The fiber surface was then treated with low-temperature plasma technology, with the discharge power controlled at 100W, the treatment time at 10 minutes, and the gas flow rate at 10L / min. Finally, microwave radiation pretreatment was performed using 2450MHz microwaves for 5 minutes, with a circulating water cooling system used during the radiation process. S2, Blending process: S2.1 Blending ratio: set at 40% type A short fiber and 60% type B short fiber; S2.2 Humidification: Before blending, the two types of short fibers are pre-humidified to control the moisture content to 8%; S2.3 Layered Alternating Mixing: The blending method is to first evenly lay a layer of type A short fibers, then lay a layer of type B short fibers, and so on alternately; S2.4 Refined Blending: Type A and Type B short fibers are classified by length and fineness: Type A short fibers are divided into three categories according to length: short, medium, and long, and also into three grades of fineness: fine, medium, and coarse; Type B short fibers are classified in the same way; when laying the first layer of Type A short fibers, they are arranged in order from fine to coarse and from short to long; then the first layer of Type B short fibers is laid, also in order from fine to coarse and from short to long, but at a 45-degree angle to the arrangement direction of Type A short fibers; S2.5 Laying: Use automatic lay-up equipment; and use ultrasonic-assisted blending with a frequency set to 30kHz and an action time of 20 minutes to monitor the fiber laying uniformity in real time. Through multiple high-definition cameras and image recognition technology installed on the automatic lay-up equipment, once an uneven area is detected, the working parameters of the nozzle are automatically adjusted immediately. S3. Spinning preparation: Use spinning auxiliaries: containing 5% silicone oil, 3% antistatic agent and 2% softener; S4. Spinning process: In high-speed rotating airflow spinning technology, the airflow speed is set to 300m / s and the spinning twist is 1000 twists / m. S5. Post-processing: S5.1 Temperature control: The heat setting temperature is controlled at 180℃, the stretching ratio is 1.5 times, and the duration is 10 minutes; S5.2 Introduce environmentally friendly finishing agents, select tea tree extract and aloe vera extract at a concentration of 8%, soak for 20 minutes, control the pH value of the soaking solution between 5.5 and 6.5, and control and adjust the temperature of the soaking solution between 35℃ and 45℃. S5.

3. Use ultraviolet irradiation with an intensity of 100W / m² for 15 minutes. S5.

4. Low-temperature vacuum drying is adopted, with the vacuum degree controlled at -0.08MPa, the temperature at 50℃, and the drying time at 30 minutes.

2. The production process for making polyester yarn from short fibers as described in claim 1, characterized in that: In S2, the blending room maintains a constant temperature and humidity environment, with the temperature controlled at 25℃±2℃ and the relative humidity controlled at 60%±5%.

3. The production process for making polyester yarn from short fibers as described in claim 1, characterized in that: In S3, when preparing spinning auxiliaries, first mix the silicone oil and antistatic agent thoroughly, then add the softener and stir evenly; control the electrostatic field strength at 50kV / m and the action time at 15 minutes.

4. The production process for making polyester yarn from short fibers as described in claim 1, characterized in that: In S4, a high-precision tension sensor is used to monitor the spinning tension in real time. The sensor is installed at the spinning spindle, the guide wheel or guide rod, or in front of the yarn winding device.

5. The production process for making polyester yarn from short fibers as described in claim 1, characterized in that: In S5.2, a circulating stirring device is used during the soaking process.

6. The production process for making polyester yarn from short fibers as described in claim 1, characterized in that: In S5.2, ultrasonic-assisted penetration technology is also introduced, with the ultrasonic frequency set at 40kHz and the action time at 10 minutes.

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