Textile dyeing and finishing process based on dynamic reaction conditions

Abstract

The invention discloses a textile dyeing and finishing process based on dynamic reaction conditions, relates to the technical field of textile dyeing and finishing, and aims to solve the problems that a traditional textile dyeing and finishing process is poor in timeliness, difficult to accurately control and incapable of adapting to complex and changeable dyeing and finishing production environments. The dyeing and finishing process comprises the following steps: S1, textile pretreatment: preparing a pretreatment solution, putting a textile to be dyed and finished into the pretreatment solution, treating for 15-30 minutes at the temperature of 40-60 DEG C, then washing with water, removing oil stains, impurities and pretreatment solution residues on the surface of the textile, and drying at the temperature of 80-100 DEG C, so as to obtain the textile; the textile is in a clean and loose-fiber state; s2, dynamic condition monitoring: installing a plurality of groups of sensors at key parts of the dyeing and finishing equipment, and arranging a control system; the method has the advantages that the problems that textile dyeing and finishing timeliness is poor, accurate control is difficult to achieve, and complex and changeable dyeing and finishing production environments cannot be adapted are effectively avoided.

Description

Technical Field

[0001] The invention relates to the technical field of textile dyeing and finishing, and more particularly to a textile dyeing and finishing process based on dynamic reaction conditions. Background Art

[0002] Textile dyeing and finishing is an important processing link to give textiles color, function and improve quality. Traditional dyeing and finishing processes are often operated according to established fixed parameters. However, in the actual production process, due to the influence of various factors, the reaction conditions in the dyeing and finishing process will continue to change. For example, the temperature in the dye tank may deviate from the set value due to uneven heating, fluctuations in the external environment temperature, etc.; the pH of the dye solution will change with factors such as the dissolution of the dye, chemical reactions, and impurities in the fabric itself; the concentration of the dye will gradually decrease as it is continuously adsorbed by the fabric; at the same time, the tension of the fabric during the transmission process will also change due to the operating status of the equipment, the winding of the fabric, etc.

[0003] If these dynamically changing reaction conditions cannot be adjusted in time, it will seriously affect the efficiency of dyeing and finishing and the performance of the product, leading to problems such as uneven dyeing, poor color fastness, and fabric damage, and it is difficult to meet the requirements of high-quality and diversified textile production. Although some dyeing and finishing processes currently perform simple manual monitoring and adjustment of some parameters, this method is not only poor in timeliness, but also difficult to achieve precise control and cannot adapt to the complex and changing dyeing and finishing production environment. In view of this, we propose a textile dyeing and finishing process based on dynamic reaction conditions. Summary of the invention

[0004] The purpose of the present invention is to provide a textile dyeing and finishing process based on dynamic reaction conditions, aiming to solve the problem that the traditional textile dyeing and finishing process is not only poor in timeliness, but also difficult to achieve precise control and unable to adapt to the complex and changeable dyeing and finishing production environment.

[0005] In order to solve the above technical problems, the present invention provides the following technical solutions: a textile dyeing and finishing process based on dynamic reaction conditions, the dyeing and finishing process comprising the following steps:

[0006] S1: Textile pretreatment: prepare a pretreatment liquid, put the textile to be dyed and finished into the pretreatment liquid, treat it at a temperature of 40-60°C for 15-30 minutes, then wash it with water to remove the oil, impurities and pretreatment liquid residue on the surface of the textile, and then dry it at 80-100°C to make the textile clean and loose in fiber;

[0007] S2: Dynamic condition monitoring: multiple sets of sensors are installed at key locations of dyeing and finishing equipment, and a control system is set up. Each sensor transmits the collected real-time data to the control system at least once every 2 seconds to ensure the timeliness and accuracy of the data;

[0008] S3: Process optimization and adjustment: The control system constructs an analysis module based on big data analysis and machine learning algorithms, and is pre-trained with a large number of dyeing and finishing process parameters and corresponding product quality data, so as to perform real-time analysis based on the received sensor data and generate corresponding process adjustment instructions;

[0009] S4: Dyeing and finishing: According to the purpose and production requirements of the textiles, one or more of the following dyeing and finishing methods, such as dip dyeing, pad dyeing, and printing dyeing and finishing, are selected for dyeing and finishing operations;

[0010] S5: Post-treatment: After dyeing and finishing, the textiles are washed in a multi-stage countercurrent washing method. The washing temperature is 30-50°C, and the water flow rate is adaptively adjusted according to the weight and material of the fabric. Then, soaping, color fixing, drying and shaping are carried out in sequence.

[0011] Preferably, in the above step S1, the pretreatment liquid contains 1%-5% of a degreasing agent, 0.5%-2% of a penetrant and 1%-3% of a water softener by mass fraction, the degreasing agent is a composite degreasing agent containing a surfactant and a biological enzyme, the penetrant is a composite penetrant formed by compounding anionic and non-ionic surfactants, and the water softener is an organic chelating agent capable of chelating metal ions.

[0012] Preferably, in the above step S2, the multiple groups of sensors installed include a temperature sensor, a pH sensor, a dye concentration sensor, a fabric tension sensor and a flow sensor, and the accuracy of each sensor is ±0.5°C, ±0.1pH, ±1g / L, ±1N and ±5% respectively;

[0013] The temperature sensor is installed in a multi-point distributed manner on the inner wall of the dye vat and the dye circulation pipeline to monitor the temperature changes in the dyeing and finishing process in real time. The pH sensor is inserted into the dye liquid through a corrosion-resistant probe to detect the pH of the dye liquid in real time. The dye concentration sensor is based on the principle of spectral analysis and determines the dye concentration by detecting the absorbance change of the dye liquid at a specific wavelength. The fabric tension sensor is installed at multiple positions on the fabric transmission path to monitor the tension of the fabric at different stages. The flow sensor is set at the dye inlet and outlet pipeline to monitor the flow of the dye liquid.

[0014] Preferably, in the above step S4, when the dyeing and finishing is exhaust dyeing, the bath ratio is controlled at 1:6-1:15, the dye liquor and the fabric are fully mixed by a stirring device, the stirring speed is dynamically adjusted according to the viscosity of the dye liquor and the weight of the fabric, and the stirring time is 20-40 minutes;

[0015] When the dyeing and finishing is pad dyeing, the padding rate is controlled at 50%-70%, and the fabric is evenly squeezed by the roller. The pressure of the roller is fed back by the pressure sensor and adjusted in real time by the control system to ensure that the fabric is evenly loaded with liquid.

[0016] When dyeing and finishing is printing, an environmentally friendly printing paste is used. The printing paste is a mixture of natural polysaccharide paste and synthetic polymer thickener in a mass ratio of 1: (0.5-1.5), and is matched with high-precision printing equipment to ensure that the printed pattern is clear, colorful, and has good fastness.

[0017] Preferably, in the above step S5, when soaping, a soaping agent with a mass fraction of 1%-3% is used, and soaping is performed at a temperature of 40-50° C. for 10-20 minutes to remove floating color on the surface of the textile;

[0018] When performing color fixing treatment, a formaldehyde-free color fixing agent is used, and the amount used is 0.5%-2% of the weight of the textile. The treatment is carried out at a temperature of 50-60°C for 15-25 minutes to enhance the color fastness of the textile.

[0019] When drying, the drying temperature is set at 80-100℃ according to the material of the textiles, and hot air circulation is used to ensure that the textiles are dried evenly and avoid local overheating;

[0020] During shaping, the shaping temperature is 150-170°C, and the shaping time is 15-30 seconds. At the same time, softening finishing agents and waterproof finishing agents can be added as needed to give the textiles corresponding functional properties, and finally obtain dyed and finished textile products that meet quality requirements.

[0021] Preferably, the biological enzyme in the composite degreasing agent is a mixture of lipase, protease and amylase, and the mass ratio thereof is 1:(0.8-1.2):(0.5-1), and the enzyme activity of lipase is not less than 8000U / g, the enzyme activity of protease is not less than 6000U / g, and the enzyme activity of amylase is not less than 5000U / g.

[0022] Preferably, the formaldehyde-free color fixing agent is a polycationic color fixing agent with a molecular weight between 5000 and 10000, which combines with dye molecules through electrostatic adsorption to enhance the color fastness of textiles.

[0023] Preferably, the softening finishing agent is an organosilicon softener having an ammonia value between 0.2 and 0.6, which can effectively improve the feel of the textile, making it soft and smooth, while not affecting the color fastness and other properties of the textile.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention can monitor various dynamic reaction conditions in the dyeing and finishing process in real time and accurately, including temperature, pH, dye concentration, fabric tension, and dye flow rate, etc., by installing multiple groups of high-precision sensors (such as temperature sensors with an accuracy of ±0.5°C and pH sensors with an accuracy of ±0.1pH, etc.) at key parts of the dyeing and finishing equipment. In addition, the control system can generate accurate process adjustment instructions in real time based on the analysis module constructed by big data analysis and machine learning algorithms based on sensor data, and respond to situations such as temperature deviation, pH change, insufficient dye concentration, and abnormal fabric tension in a timely manner, effectively avoiding quality problems such as uneven dyeing, poor color fastness, and fabric damage, ensuring the consistency and high quality of textile dyeing and finishing effects, so that the final product can better meet the high-quality and diversified market demand.

[0026] 2. The present invention transmits the collected data to the control system at a frequency of at least once every 2 seconds through sensors, achieving near real-time data feedback. The control system can quickly make process adjustments. The entire process does not require frequent human intervention for observation and adjustment, reducing rework caused by unreasonable process parameters and significantly improving the overall efficiency of dyeing and finishing production.

[0027] 3. The present invention can not only perform conventional soaping, color fixing, drying and shaping operations, but also add finishing agents with different functions according to actual needs, such as softening finishing agent (organic silicone softener with an ammonia value between 0.2 and 0.6 is selected to improve the feel without affecting the color fastness and other properties), waterproof finishing agent, and in the dyeing and finishing execution link, different dyeing and finishing methods such as immersion dyeing, pad dyeing and printing can be selected as needed for combined operation, so that textiles can be flexibly given corresponding functional characteristics according to different uses and customer requirements, broadening the application range of the product and better meeting the diverse market needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the dyeing and finishing process flow in the present invention. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0030] Embodiment 1

[0031] Pure cotton fabric was selected as the textile to be dyed and finished, and was placed in a pretreatment solution in which the mass concentration of the degreasing agent was 3%, the mass concentration of the penetrant was 1%, and the mass concentration of the water softener (disodium ethylenediaminetetraacetic acid) was 2%. The fabric was treated at 60°C for 30 minutes, then washed with normal temperature water, and then dried at 100°C to obtain the pretreated pure cotton fabric.

[0032] The pretreated pure cotton fabric is placed in a dye vat for dyeing. The dye vat is equipped with the above-mentioned high-precision temperature sensor, pH sensor, dye concentration sensor and fabric tension sensor. During the dyeing process, the temperature, pH value, dye concentration and fabric tension data are collected in real time and transmitted to the control system.

[0033] This dyeing uses reactive dyes, the preset dyeing and finishing temperature range is 80-100℃, the preset pH range is 7-9, the preset dye concentration effective range is 20-30g / L, and the preset fabric safety tension range is 20-50N. When the control system detects that the temperature in the dye vat is lower than 80℃, it automatically starts the heating device and adjusts the heating power to bring the temperature back to the set range; if the pH value is lower than 7, it automatically adds an appropriate amount of sodium carbonate solution to adjust the pH; when the dye concentration drops below 20g / L, add the corresponding reactive dyes; if the fabric tension exceeds 50N, adjust the tension by reducing the speed of the fabric drive motor to bring it back to a safe range.

[0034] The dyeing is carried out by immersion dyeing, the bath ratio is 1:10, the dyeing time is 40 minutes, and after dyeing, softening finishing is carried out by adding softener (silicone softener is selected) in an amount of 2% of the weight of the fabric, the processing temperature is 40°C, and the processing time is 20 minutes.

[0035] The fabric is first washed at 40°C with three-stage countercurrent washing, then soaped with a soaping agent having a mass concentration of 2% at 50°C for 15 minutes, then pickled with a dilute hydrochloric acid solution having a mass concentration of 0.8% for 10 minutes, then dried at 100°C, and finally set at 160°C to obtain a dyed and finished pure cotton fabric product with uniform dyeing, high color fastness and soft hand feel.

[0036] Embodiment 2

[0037] This embodiment is basically the same as the first embodiment, except that polyester fiber fabric is selected as the object to be dyed and finished, the mass concentration of the degreasing agent in the pretreatment liquid is 2%, the mass concentration of the penetrant is 1.5%, the mass concentration of the water softener (aminotrimethylenephosphonic acid) is 1.5%, the treatment is carried out at 70°C for 40 minutes, and the fabric is dried at 110°C after washing.

[0038] The pretreated polyester fiber fabric is placed in the dyeing vat for dyeing. The data is monitored in real time by various sensors and transmitted to the control system for dynamic monitoring during the dyeing process.

[0039] When using disperse dyes, the preset dyeing and finishing temperature range is 120-140℃, the preset pH range is 4-6, the preset effective dye concentration range is 10-20g / L, and the preset fabric safety tension range is 30-60N. According to the sensor feedback data, the control system adjusts the dye vat temperature, dye solution pH, dye concentration and fabric tension accordingly to keep them within a reasonable range.

[0040] The dyeing is carried out by pad dyeing with a padding rate of 60%. After pad dyeing, anti-wrinkle finishing is carried out by adding an anti-wrinkle finishing agent in an amount of 3% of the weight of the fabric, the processing temperature is 160° C., and the processing time is 30 seconds.

[0041] The product is washed with water at 50°C, cleaned with four-stage countercurrent, and then soaped with a soaping agent having a mass concentration of 1.5% at 45°C for 20 minutes, then dried at 110°C, and finally set at 170°C to obtain a polyester fiber fabric product after dyeing and finishing, which has uniform dyeing, good wrinkle resistance, and color fastness that meets the requirements.

[0042] The embodiments of the present invention disclose preferred embodiments, but are not limited thereto. A person skilled in the art can easily understand the spirit of the present invention based on the above embodiments and make different extensions and changes. However, as long as they do not deviate from the spirit of the present invention, they are all within the protection scope of the present invention.

Claims

1. A textile dyeing and finishing process based on dynamic reaction conditions, characterized in that: The dyeing and finishing process includes the following steps: S1: Textile pretreatment: prepare a pretreatment liquid, put the textile to be dyed and finished into the pretreatment liquid, treat it at a temperature of 40-60°C for 15-30 minutes, then wash it with water to remove the oil, impurities and pretreatment liquid residue on the surface of the textile, and then dry it at 80-100°C to make the textile clean and loose in fiber; S2: Dynamic condition monitoring: multiple sets of sensors are installed at key locations of dyeing and finishing equipment, and a control system is set up. Each sensor transmits the collected real-time data to the control system at least once every 2 seconds to ensure the timeliness and accuracy of the data; S3: Process optimization and adjustment: The control system constructs an analysis module based on big data analysis and machine learning algorithms, and is pre-trained with a large number of dyeing and finishing process parameters and corresponding product quality data, so as to perform real-time analysis based on the received sensor data and generate corresponding process adjustment instructions; S4: Dyeing and finishing: According to the purpose and production requirements of the textiles, one or more of the following dyeing and finishing methods, such as dip dyeing, pad dyeing, and printing dyeing and finishing, are selected for dyeing and finishing operations; S5: Post-treatment: After dyeing and finishing, the textiles are washed in a multi-stage countercurrent washing method. The washing temperature is 30-50°C, and the water flow rate is adaptively adjusted according to the weight and material of the fabric. Then, soaping, color fixing, drying and shaping are carried out in sequence.

2. A textile dyeing and finishing process based on dynamic reaction conditions according to claim 1, characterized in that: In the above step S1, the pretreatment liquid contains 1%-5% of a degreasing agent, 0.5%-2% of a penetrant and 1%-3% of a water softener by mass fraction, the degreasing agent is a composite degreasing agent containing a surfactant and a biological enzyme, the penetrant is a composite penetrant formed by compounding anionic and non-ionic surfactants, and the water softener is an organic chelating agent capable of chelating metal ions.

3. A textile dyeing and finishing process based on dynamic reaction conditions according to claim 1, characterized in that: In the above step S2, the multiple groups of sensors installed include a temperature sensor, a pH sensor, a dye concentration sensor, a fabric tension sensor, and a flow sensor, and the accuracy of each sensor is ±0.5°C, ±0.1pH, ±1g / L, ±1N, and ±5% respectively; The temperature sensor is installed in a multi-point distributed manner on the inner wall of the dye vat and the dye circulation pipeline to monitor the temperature changes in the dyeing and finishing process in real time. The pH sensor is inserted into the dye liquid through a corrosion-resistant probe to detect the pH of the dye liquid in real time. The dye concentration sensor is based on the principle of spectral analysis and determines the dye concentration by detecting the absorbance change of the dye liquid at a specific wavelength. The fabric tension sensor is installed at multiple positions on the fabric transmission path to monitor the tension of the fabric at different stages. The flow sensor is set at the dye inlet and outlet pipeline to monitor the flow of the dye liquid.

4. A textile dyeing and finishing process based on dynamic reaction conditions according to claim 1, characterized in that: In the above step S4, when the dyeing and finishing is exhaust dyeing, the bath ratio is controlled at 1:6-1:15, and the dye liquor and the fabric are fully mixed by a stirring device, and the stirring speed is dynamically adjusted according to the viscosity of the dye liquor and the weight of the fabric, and the stirring time is 20-40 minutes; When the dyeing and finishing is pad dyeing, the padding rate is controlled at 50%-70%, and the fabric is evenly squeezed by the roller. The pressure of the roller is fed back by the pressure sensor and adjusted in real time by the control system to ensure that the fabric is evenly loaded with liquid. When dyeing and finishing is printing, an environmentally friendly printing paste is used. The printing paste is a mixture of natural polysaccharide paste and synthetic polymer thickener in a mass ratio of 1: (0.5-1.5), and is matched with high-precision printing equipment to ensure that the printed pattern is clear, colorful, and has good fastness.

5. A textile dyeing and finishing process based on dynamic reaction conditions according to claim 1, characterized in that: In the above step S5, when soaping, a soaping agent with a mass fraction of 1% to 3% is used, and soaping is performed at a temperature of 40 to 50° C. for 10 to 20 minutes to remove floating color on the surface of the textile; When performing color fixing treatment, a formaldehyde-free color fixing agent is used, and the amount used is 0.5%-2% of the weight of the textile. The treatment is carried out at a temperature of 50-60°C for 15-25 minutes to enhance the color fastness of the textile. When drying, the drying temperature is set at 80-100℃ according to the material of the textiles, and hot air circulation is used to ensure that the textiles are dried evenly and avoid local overheating; During shaping, the shaping temperature is 150-170°C, and the shaping time is 15-30 seconds. At the same time, softening finishing agents and waterproof finishing agents can be added as needed to give the textiles corresponding functional properties, and finally obtain dyed and finished textile products that meet quality requirements.

6. A textile dyeing and finishing process based on dynamic reaction conditions according to claim 2, characterized in that: The biological enzyme in the composite degreasing agent is a mixture of lipase, protease and amylase, and the mass ratio thereof is 1:(0.8-1.2):(0.5-1), and the enzyme activity of the lipase is not less than 8000U / g, the enzyme activity of the protease is not less than 6000U / g, and the enzyme activity of the amylase is not less than 5000U / g.

7. A textile dyeing and finishing process based on dynamic reaction conditions according to claim 5, characterized in that: The formaldehyde-free color fixing agent is a polycationic color fixing agent with a molecular weight between 5000 and 10000. It combines with dye molecules through electrostatic adsorption to enhance the color fastness of textiles.

8. A textile dyeing and finishing process based on dynamic reaction conditions according to claim 5, characterized in that: The softening finishing agent is an organic silicon softener, and its ammonia value is between 0.2 and 0.6, which can effectively improve the feel of the textiles, making them soft and smooth, while not affecting the color fastness and other properties of the textiles.

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