Process for producing occupational tooling fabric from colored polyester and colored cotton fiber spinning regenerated material

Abstract

The invention discloses a technology for producing occupational frock fabric from colored polyester and colored cotton fiber spinning regenerated materials, and relates to the technical field of spinning and printing and dyeing, and the technology comprises the following steps: opening and pretreating a colored polyester regenerated material and a colored cotton regenerated material to prepare spinnable fibers; spinning polyester cotton or cotton polyester blended yarns by utilizing the spinnable fibers by adopting an air spinning process; weaving the yarns into grey cloth; carrying out dyeing treatment on the gray fabric; the dyed gray fabric is subjected to finishing treatment through insoluble resin, the insoluble resin contains bio-based components and a nano auxiliary agent, and the coating is formed through the steps of dipping, pre-drying, calendaring and curing. The finished fabric manufactured by the process provided by the invention is suitable for low-end markets. And colored polyester and colored cotton regenerated materials are used, so that carbon emission is reduced, and chemical pollution is reduced. Better air permeability and comfort are achieved; the yarn and fabric quality is improved through the innovative process. Terylene leftovers and cotton waste are fully utilized, and the resource utilization rate is increased.

Description

Technical Field

[0001] The invention relates to the technical field of textiles and printing and dyeing, in particular to a process for producing professional workwear fabrics from recycled materials of colored polyester and colored cotton fiber spinning. Background Art

[0002] Workwear fabrics are a highly mature product category in the textile printing and dyeing industry, with a well-developed industrial chain. Significant industrial clusters have formed, particularly in Chengdu, Leshan, and Mianyang, Sichuan, encompassing the entire supply chain from raw materials and spinning to weaving and dyeing, and home to thousands of manufacturers. Existing fabrics offer a wide variety of specifications and colors, with over a thousand different production processes. However, existing technologies suffer from the following deficiencies: The use of new polyester fibers and cotton results in high energy consumption and increased carbon emissions; high raw material and processing costs increase procurement costs by 20% to 40% for low-end customers (such as prison uniforms, sanitation uniforms, and delivery uniforms), resulting in a low cost-performance ratio; all-polyester fabrics exhibit poor breathability and wearability; polyester dyeing requires high temperatures and pressures, and weaving uses PVA sizing and water-jet looms, increasing environmental pollution; and over 60% of recycled colored polyester and cotton is used in low-value-added products, resulting in a significant waste of resources. Summary of the Invention

[0003] In order to solve the above technical problems, the present invention provides a process for producing occupational workwear fabrics from recycled materials of colored polyester and colored cotton fiber spinning. The specific technical solution is as follows:

[0004] A process for producing professional workwear fabrics from recycled materials of colored polyester and colored cotton fiber spinning, comprising the following steps:

[0005] a. Opening and pretreating the recycled polyester and cotton materials to prepare spinnable fibers;

[0006] b using air-spinning process, the use of the spinnable fiber spinning polyester-cotton or cotton-polyester blended yarn;

[0007] c. weaving the yarn into a greige fabric;

[0008] d. dyeing the grey cloth;

[0009] e. Finishing the dyed grey fabric with an insoluble resin, wherein the insoluble resin contains a bio-based component and a nano-additive, and forming a coating through the steps of impregnation, pre-baking, calendering and curing.

[0010] Preferably, the opening and pretreatment of the dyed polyester recycled material in step a specifically includes:

[0011] The polyester recycled material is opened by a single licker-in opener, and sprayed with an aqueous solution containing an antistatic agent to control the moisture regain at 2% to 3%;

[0012] The mixture is allowed to stand for 36 to 48 hours to prepare spinnable polyester fibers.

[0013] Preferably, the opening and pretreatment of the colored cotton recycled material in step a specifically includes:

[0014] Cut the colored cotton recycled material into sections and stack them, spray them with an aqueous solution containing 0.05% to 0.1% swelling agent, and control the moisture regain to 8% to 9%;

[0015] The fiber is opened through the waste yarn opening production line to control the main fiber length to 20-25 mm and the short fiber rate to be less than 30%.

[0016] Preferably, in step b, the air-spinning process specifically includes the following processes: cotton picking, heavy object separation, multi-bin cotton mixing, fine cotton opening, dust removal, carding, three-pass drawing, and air-spinning.

[0017] Preferably, the parameters of the spinning process in step b include:

[0018] The weight of the carded strip is 25-35g / 5m;

[0019] The carding sliver delivery speed is 250-300m / min;

[0020] The drawing speed is 600-700m / min;

[0021] The rotor speed is 80,000 to 120,000 rpm, and the spinning speed is 120 to 150 m / min.

[0022] Preferably, the dyeing treatment in step d specifically includes the following process: unwrapping and seaming of the grey cloth, singeing, soaking and cold rolling and standing, scouring and bleaching, mercerizing, and dyeing; wherein the soaking and cold rolling and standing step uses a solution containing 2 to 5 g / L of penetrant and 4 to 8 g / L of discoloring agent, and the cold rolling pressure is 0.1 to 0.2 MPa.

[0023] Preferably, the insoluble resin in step e is made of the following components: by weight, 70% to 80% of modified polyurethane or water-based acrylic resin, 10% to 15% of bio-based polyol, 1% to 3% of nano-silicon oxide or nano-zinc oxide, 2% to 5% of a cross-linking agent, and the balance being an aqueous dispersant.

[0024] Preferably, in step e:

[0025] The impregnation specifically includes: impregnating the dyed grey cloth in the insoluble resin solution with a concentration of 10% to 15% and a liquid squeeze rate of 60% to 80%;

[0026] The pre-baking temperature is 80-100°C and the time is 2-3 minutes;

[0027] The calendering temperature is 120-140°C and the pressure is 0.2-0.3 MPa;

[0028] The curing adopts a staged curing method, first pre-curing at 100° C. for 30 seconds, and then curing at 150-180° C. for 1-2 minutes.

[0029] Preferably, the impregnation is performed with the aid of ultrasound.

[0030] Preferably, the insoluble resin solution further comprises 0.5% to 1% of a silicone softener.

[0031] The process for producing professional workwear fabrics from recycled materials of colored polyester and colored cotton fiber spinning provided by the present invention has the following beneficial effects:

[0032] 1. The cost is low, and the finished fabrics are suitable for the low-end market (such as prison uniforms, security uniforms, sanitation uniforms, takeaway uniforms, and courier uniforms).

[0033] 2. Use recycled polyester and cotton materials to reduce carbon emissions by more than 90%, reduce high temperature and high pressure dyeing and chemical pollution, and the production process is green and environmentally friendly.

[0034] 3. Compared with pure polyester fabrics, polyester-cotton blended fabrics have better breathability and comfort, and are suitable for low-end professional workwear needs; innovative technology improves the quality of yarn and fabric and compensates for the surface defects of recycled materials.

[0035] 4. Make full use of polyester scraps (cutting flowers, car belly flowers) and cotton waste from the color spinning factory, turning waste into treasure, improving resource utilization and reducing raw material costs. DETAILED DESCRIPTION

[0036] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention is described in detail below. The description in this section is only exemplary and explanatory and should not have any limiting effect on the scope of protection of the present invention.

[0037] This embodiment provides a process for producing workwear fabrics from recycled materials of colored polyester and colored cotton fibers, comprising the following steps:

[0038] a. Opening and pre-treating the recycled polyester and cotton materials to prepare spinnable fibers.

[0039] b. Use air-spinning technology to use spinnable fibers to spin polyester-cotton or cotton-polyester blended yarns.

[0040] c. Weaving the yarn into grey fabric.

[0041] d. Dyeing the grey cloth.

[0042] e. The dyed grey fabric is finished with an insoluble resin, wherein the insoluble resin contains bio-based components and nano-additives, and a coating is formed through the steps of impregnation, pre-baking, calendering and curing.

[0043] Among them, this embodiment uses a unique process to use the polyester scraps from the color spinning factory to open 2-5 kinds of polyester chopper flowers and belly flowers with similar colors through a single roller opener, and spray them with an aqueous solution of antistatic agent to keep the moisture regain between 2-3%. Let it stand for 36-48 hours to make it into a polyester single fiber state with good spinnability.

[0044] The pure cotton scraps from the color spinning factory are put into the waste yarn opening production line with unique process configuration. After opening and spraying with a tax solution containing swelling solution (waste yarn before opening, cotton layer after opening), the moisture regain is controlled at 8%-9%. After standing for 24-36 hours, the main length of the cotton fiber after opening is about 23mm, and the short fiber rate is below 30%.

[0045] The company will use the most advanced spinning equipment available after 2023. A multi-bin (10+ bale) mixed-opening machine will be added to the conventional blowing and carding process, and the drawing process will be expanded from two to three stages. This equipment and process configuration ensures the quality of the finished fabric and the efficiency of the spinning and weaving processes.

[0046] A cold rolling process is added to the dyeing process, and only environmentally friendly reactive dyes are used to produce polyester-cotton or polyester-cotton fabrics.

[0047] The process for producing professional workwear fabrics from recycled polyester and cotton fiber spinning provided in this embodiment has the following beneficial effects:

[0048] 1. The cost is low, and the finished fabrics are suitable for the low-end market (such as prison uniforms, security uniforms, sanitation uniforms, takeaway uniforms, and courier uniforms).

[0049] 2. Use recycled polyester and cotton materials to reduce carbon emissions by more than 90%, reduce high temperature and high pressure dyeing and chemical pollution, and the production process is green and environmentally friendly.

[0050] 3. Compared with pure polyester fabrics, polyester-cotton blended fabrics have better breathability and comfort, and are suitable for low-end professional workwear needs; innovative technology improves the quality of yarn and fabric and compensates for the surface defects of recycled materials.

[0051] 4. Make full use of polyester scraps (cutting flowers, car belly flowers) and cotton waste from the color spinning factory, turning waste into treasure, improving resource utilization and reducing raw material costs.

[0052] Furthermore, the opening and pretreatment of the colored polyester recycled material in step a specifically includes:

[0053] The colored polyester recycled material is opened by a single licker-in opener and sprayed with an aqueous solution containing an antistatic agent to control the moisture regain to 2% to 3%.

[0054] The mixture is allowed to stand for 36 to 48 hours to prepare spinnable polyester fibers.

[0055] Furthermore, the opening and pretreatment of the colored cotton recycled material in step a specifically includes:

[0056] Cut the colored cotton recycled materials into sections and stack them, spray them with an aqueous solution containing 0.05% to 0.1% of a swelling agent, and control the moisture regain to be 8% to 9%.

[0057] The fiber is opened through the waste yarn opening production line to control the main fiber length to 20-25 mm and the short fiber rate to be less than 30%.

[0058] Furthermore, in step b, the air-jet spinning process specifically includes the following processes: cotton grabbing, heavy object separation, multi-bin cotton mixing, fine cotton opening, dust removal, carding, three-pass drawing, and air-jet spinning.

[0059] Furthermore, the parameters of the spinning process in step b include:

[0060] The weight of the raw strip is 25-35g / 5m.

[0061] The carding speed is 250-300m / min.

[0062] The drawing speed is 600-700m / min.

[0063] The rotor speed is 80,000 to 120,000 rpm, and the spinning speed is 120 to 150 m / min.

[0064] Furthermore, the dyeing process in step d specifically includes the following steps: unwrapping and seaming of the grey fabric, singeing, wet cold rolling and static evaporation, scouring and bleaching, mercerizing, and dyeing. The wet cold rolling and static evaporation step uses a solution containing 2-5 g / L of penetrant and 4-8 g / L of discoloring agent, and the cold rolling pressure is 0.1-0.2 MPa.

[0065] Furthermore, the insoluble resin in step e is made of the following components: by weight, 70% to 80% of modified polyurethane or water-based acrylic resin, 10% to 15% of bio-based polyol, 1% to 3% of nano-silicon oxide or nano-zinc oxide, 2% to 5% of a cross-linking agent, and the balance being an aqueous dispersant.

[0066] Furthermore, in step e:

[0067] The dipping specifically includes: dipping the dyed grey cloth into an insoluble resin solution with a concentration of 10% to 15% and a liquid extraction rate of 60% to 80%.

[0068] The pre-baking temperature is 80-100°C and the time is 2-3 minutes.

[0069] The calendering temperature is 120-140°C and the pressure is 0.2-0.3 MPa.

[0070] The curing adopts a staged curing method, first pre-curing at 100℃ for 30 seconds, and then curing at 150-180℃ for 1-2 minutes.

[0071] Furthermore, the impregnation is assisted by ultrasonic treatment.

[0072] Furthermore, the insoluble resin solution also includes 0.5% to 1% of a silicone softener.

[0073] This embodiment utilizes recycled materials from spinning mills that produce colored polyester and colored cotton, and processes them into spinning raw materials through innovative processes and methods. By innovating the spinning process and inventing innovative dyeing processes, the entire industry chain process and technology are changed to produce green, low-carbon, environmentally friendly, and highly cost-effective medium- and dark-colored polyester-cotton professional workwear fabrics that meet the needs of the low-end market.

[0074] Specifically include the following steps.

[0075] 1. Procurement, processing and use of spinning raw materials:

[0076] <1>, polyester color spinning knife flower, car belly flower

[0077] 1. We purchase from the dyed spinning mills of Huafu, Bailong, Jiangyin, and Zhangjiagang at designated locations and on a regular basis. The main colors are blue, gray, red, yellow, and black. The specific color to be used is determined based on the specific product. These mills produce tens of thousands of tons of this recycled material annually.

[0078] 2. Mix similar colors together and feed them into a single licker-in opener to separate the bundled fibers into single fibers. At the end of the opening process, a solution containing an electrostatic oil (2-3%) is automatically and evenly sprayed on the cotton layer to control the moisture regain to 3-5%.

[0079] 3. Use an automatic baling machine to pack the processed polyester fiber. The weight of each bag should be controlled within 140kg±2kg. Let it stand for 36-48 hours before use.

[0080] 4. Package, number and stack according to different colors (similar colors are combined into one).

[0081] 5. The current market ex-factory price of polyester colored fiber recycled material is 1,500 yuan / ton, the freight + processing fee is 500 yuan / ton, and the price for direct use is 2,000 yuan / ton.

[0082] 6. Usage: According to the color of the finished fabric and the proportion of polyester spun, determine the color and quantity of the polyester recycled material to be used directly.

[0083] <2>, pure cotton dyed recycled material (waste yarn)

[0084] 1. Purchase 100% cotton (or containing 3-5% polyester) colored waste yarn from Zhangjiagang, Jiangyin Color Spinning Mill, Huafu, and Bailong Color Spinning Mill. The quantity is 300-500 tons each time. All colors are acceptable.

[0085] 2. Stack the waste wires of different colors (similar colors are combined into one) in proportion and perform preliminary stacking.

[0086] 3. Use the following process to process the recycled yarn:

[0087] (1) Cut different colors into sections in proportion and stack them, let them swell and moisten and let them stand for 24-36 hours.

[0088] After sorting, the waste yarn is sent to the opening room, package by package, by color and weight. A yarn cutter cuts the waste yarn into 50-60mm stacks, each layer of which is laid out into rectangular blocks 4-5m long, 3-4m wide, and 0.3-0.4m high. A swelling liquid (made by adding a swelling agent to water at a concentration of 0.05% to 0.1%) is evenly sprayed onto each layer of the waste yarn. The amount used is 10-15% of the weight of each layer. A layer of cut waste yarn is then added, and the swelling liquid is sprayed again. This process is repeated until the waste yarn stack reaches a height of 1.5-2m. The entire stack is then covered with plastic film and left to stand for 24-36 hours.

[0089] (2) Opening of the yarn

[0090]

[0091] (Note: Cotton distribution pipeline, relay fan, dust removal equipment, wine spraying device)

[0092] (2)-2. Automatically spray water mist on the cotton layer output by the last gusset machine to control the moisture regain of the colored cotton after opening to between 9-10%.

[0093] (2)-3. The main length of the colored cotton after opening is about 23mm, and the short fiber rate is controlled below 30%.

[0094] (2)-4. The packing weight of each pack should be controlled between 138 and 142 kg. After standing for 36 hours, it can be used directly.

[0095] (3) The price of the processed recycled colored cotton is: 3,500 yuan / ton for waste yarn (containing 5% polyester), 1,000 yuan / ton for opening and processing, and 500 yuan / ton for loss, totaling 5,000 yuan / ton.

[0096] 2. Spinning method, process flow and parameters:

[0097] <1>, Spinning method: rotor spinning (air spinning)

[0098] In order to ensure the production efficiency and product quality of spinning and weaving, the selection, process and technology of spinning equipment must be at the advanced level in China. The specific configuration is as follows:

[0099] Reciprocating double-door cotton plucker → heavy object separator (equipped with fire alarm and metal suction device) → multi-bin mixed cotton opener (10 bins) → multi-bin mixed cotton opener (10 bins) (one more unit compared to conventional process) → fine cotton opener → dust remover → TC-15 carding machine (all the above equipment must be German Tru equipment produced after 2023) → first draw frame → second draw frame → third draw frame (Swiss Rieter equipment produced after 2023) → A9 (German Schlafhorst air-spinning machine or Swiss Rieter R70 equipment).

[0100] Utilizing the most advanced equipment, the blowing-carding line incorporates a multi-bin blending and opening machine and a three-stage drawing frame, compared to conventional processes. This significantly impacts polyester and cotton blends, ensuring uniform fiber distribution through the use of a cotton box blend, spinning efficiency, weaving efficiency, yarn quality, and the uniform color of the finished product. Currently, to ensure a consistent blend ratio and a uniform blend of the two fibers, separate blowing-carding lines are used to produce pure polyester and pure cotton slivers, with sliver blending implemented throughout the drawing process.

[0101] <2> Spinning feeding and main parameters of each process

[0102] 1. Product range: Based on the above two types of recycled fibers, polyester and pure cotton, we mainly produce products with different proportions of polyester-cotton and cotton-polyester (CVC) and different yarn counts. The details are as follows:

[0103]

[0104] 2. Feeding ratio and arrangement order

[0105] (1) Calculate the number of polyester and cotton bales to be packed based on the polyester and cotton content of the product being spun, and the weight of the raw materials per bale. In principle, cotton fiber loss is significant during the production process, so the weight of the cotton bales should be 2% higher than the blending ratio of the product. The total weight of each box on the Tru Double Width Reciprocating Broom is 30-40 tons.

[0106] (2) The raw material packages of polyester and cotton fibers are packed in boxes evenly spaced according to the proportion.

[0107] 3. Main process parameters

[0108]

[0109] After the above equipment selection, process configuration and parameter optimization, it is ensured that the quality level of the spun yarn count is within 10% of the Uster bulletin level under the same raw material ratio, and the weaving efficiency is ensured to be above 95% at a speed of 600 rpm.

[0110] 3. Weaving process and process design:

[0111] Weaving process: warping → sizing → reeding → weaving → inspection → packaging → shipment.

[0112] Weaving processes require different parameters depending on the type and specification of the fabric. With the widespread adoption of high-speed shuttleless looms and improved yarn quality, the rate of first-class grey fabric off the machine has reached over 90%, and the process parameters have been significantly optimized. Specific parameters are not provided here.

[0113] 4. Dyeing and finishing process and technology:

[0114] <1>, process flow

[0115] Grey cloth unwrapping and seaming → singeing → soaking and cold rolling → boiling and bleaching (de-sizing) → mercerizing →

[0116]

[0117] <2>, Process Description

[0118] This process has two significant innovations compared to the existing process for professional workwear fabrics (polyester-cotton):

[0119] 1. Polyester fiber does not need to be dyed. The original color of polyester colored fiber is used as the base color, and the pure cotton colored fiber is added with color to adjust to the color required for the fabric.

[0120] 2. Adding a cold rolling and settling process, while fading the color of the cotton component of the fabric by over 30%, allows for smooth stripping of the pure cotton color of the greige fabric during subsequent scouring and mercerizing. By adjusting the dyeing of the pure cotton fiber, it can basically meet the color requirements of over 80% of polyester-cotton professional workwear fabrics.

[0121] <3>, process technology

[0122] 1. Wet cold rolling and standing: Mix 2-5g / L of penetrant and 4-8g / L of discoloring agent with water to form a wet stripping treatment liquid, add it to the liquid tank of the cold rolling mill, control the pressure of the cold rolling mill to 0.1-0.2MPa, and then pass the grey fabric through the liquid tank at a speed of 20-60m / min at room temperature and wind it into a cloth roll of 4500-5000m / piece through the cold rolling roller. After standing at room temperature for 36-48 hours, enter the scouring and bleaching process.

[0123] 2. Scouring and bleaching process: conventional process + fading agent (3-5g / L)

[0124] 3. Mercerizing process: conventional process + hydrogen peroxide (5-10g / L), hydrogen peroxide increases color and whitens.

[0125] 4. Dyeing: (1) Low temperature and normal pressure vat dyeing (for applications with low requirements on color difference, such as prison uniforms, sanitation work clothes, etc.)

[0126] (2) Long vehicle dyeing (for those with high color requirements, such as security uniforms, takeaway uniforms, courier uniforms, etc.)

[0127] Dyeing is done according to conventional technology. The dyeing of polyester fibers is not considered. Only the pure cotton part is dyed. The color and shade of the fabric are adjusted by dyeing the pure cotton to match the original board or customer requirements.

[0128] 5. Shaping: Shaping temperature 150-200℃, width 63″±5-10mm. Radial shrinkage within 4%, lateral shrinkage below 2%.

[0129] 6. Rolling: 100-150m / roll. (Depending on the weight of the fabric).

[0130] 5. The technical points of this embodiment are summarized as follows:

[0131] The company has innovatively proposed using recycled materials from color-dyed pure polyester and pure cotton directly as spinning raw materials after physical processing. Furthermore, it has innovatively adjusted the blowing, carding, drawing, and dyeing processes, along with process innovations, to create a systematic and coordinated system. This results in a low-carbon, environmentally friendly, highly cost-effective, and relatively comfortable workwear fabric, revolutionizing the production methods of low-end pure polyester and polyester-cotton workwear fabrics.

[0132] <1>. Innovation in methods and processes for the early processing of recycled materials.

[0133] <2> In the spinning, cleaning and carding process, a multi-bin cotton mixing machine (10 bins) was creatively added to enhance the cotton mixing effect.

[0134] <3>. Add a drawing frame in the drawing process, and the three-pass drawing process will enhance the mixing effect between polyester and cotton fibers and between cotton fibers.

[0135] <4>, Two inventions and innovations were made in the dyeing process:

[0136] 1. Add a wet cold rolling static process.

[0137] 2. A revolutionary approach to dyeing polyester-cotton fabrics. Existing polyester-cotton fabrics require both the polyester portion and the cotton portion to be dyed with cationic dyes. This embodiment dyes only the pure cotton portion.

[0138] Compared with the existing technology, the beneficial effects are as follows:

[0139] This method of producing polyester-cotton fabrics for professional workwear fills the gap in low-end customer demand, subverts the existing production method, and is green, low-carbon, environmentally friendly, and has a high cost-effectiveness compared to existing similar products, bringing huge economic and social benefits.

[0140] Specific examples are provided below. The provided examples may enable those skilled in the art to more fully understand the present invention, but are not intended to limit the present invention in any way.

[0141] Examples include occupational fabrics in the following three areas, which are representative of low-end market demand.

[0142] <1>, Prisoner uniform spring and autumn fabrics

[0143] <2>, Security uniform professional fabrics

[0144] <3>, winter cotton-padded fabrics for express delivery and takeaway

[0145] To simply and intuitively illustrate the beneficial effects of the products of the present invention, a table comparing the specifications currently sold and used by customers, raw materials, and production costs along the entire supply chain (raw materials -> spinning and weaving -> dyeing) with the products of the present invention is presented.

[0146] Example 1: Prison spring and autumn prisoner uniform outer fabric (1) (2)

[0147] 1. Parameter comparison table of prisoner uniform fabrics and alternative fabrics of the present invention:

[0148]

[0149] 2. The procurement and processing methods of raw materials are as described above.

[0150] 3. Proportion and arrangement order of spinning raw materials

[0151] (1) Polyester colored fiber raw material. It accounts for 63% of the total input, of which blue fiber accounts for 40% and gray fiber accounts for 23%. (This is because the cotton fiber has about 2% more noil during the spinning process).

[0152] (2) Pure cotton colored fiber. It accounts for 37% of the total input (mixed colors).

[0153] (3) The arrangement order is: two bales of polyester and one bale of cotton, arranged in staggered order.

[0154] 4. The spinning method and process are as described above.

[0155] 5. Main spinning process parameters:

[0156]

[0157] 6. The weaving process is as described above.

[0158] 7. Warping process: Inventive fabric (1) 680 warp beams / 10 warp beams / sizing per cylinder.

[0159] Inventive fabric (2) 756 pieces / warp beam 10 warp beams / sizing per cylinder

[0160] 8. Sizing process: "PVA + modified starch" is used for sizing, and its proportion, materials, additives, temperature and time are in accordance with conventional processes.

[0161] 9. Main process parameters of weaving:

[0162] Project Name Fabric of the present invention (1) Fabric of the present invention (2) Total number of warps 6800 pieces (edge ​​yarn 48*2) 7560 pieces (edge ​​yarn 48*2) Reed 55.5#2 entry / reed 58#2 entry / reed fabric structure 2 / 2 left oblique 3 / 1 left oblique Weaving speed 600 rpm 600 rpm Upper machine width 70" 70" Lower machine width 66" 66″ Finished product width 63" 63″

[0163] 10. Dyeing process: The process is the same as above. The dyeing color is based on the color of prison uniform (1) and prison uniform (2). If there are differences in color and cylinder difference, it will not affect the wearing performance. In actual use, different batches and the same batch will show obvious color and color differences.

[0164] 11. Compared with the spring and autumn outerwear prison uniforms (1) and (2) used by prisoners in all prisons under the jurisdiction of the Ministry of Justice, the patented fabric (1) and the invented fabric (2) of this invention have the following social and economic benefits:

[0165] (1) Prison uniforms (1) and (2) are made entirely of new polyester filaments (warp and weft yarns) from petrochemical production. During the production process, a large amount of oil and energy is consumed, significantly increasing carbon emissions. However, the raw materials used in the fabrics (1) and (2) of the present invention are 100% recycled fiber, which is green, low-carbon, and environmentally friendly. Furthermore, prison uniforms are woven using a water-jet machine and dyed at high temperatures and high pressures, significantly impacting the environment.

[0166] (2) Prison uniforms (2) (2) are made of 100% polyester. They are not breathable and have poor wearability. The warp and weft yarns are all filaments, which can easily fall off during cutting and sewing, making them difficult to sew.

[0167] (3) Compared with prison uniforms (1) and (2), the fabrics (1) and (2) of the present invention have a large price difference between their cost price and market price. According to the calculation results of the "Parameter comparison table of prison uniform fabrics and alternative fabrics of the present invention" in Example 1:

[0168] A: The price of the invented fabric (1) is 2.6 yuan per meter lower than that of the prison uniform (1), saving more than 30% of the purchasing cost.

[0169] B: The price of the invented fabric (2) is 3.3 yuan / meter lower than that of the prison uniform (2), saving 30% of the purchasing cost.

[0170] According to online inquiries, there were 1,717,924 prisoners serving sentences nationwide in 2021, and about 2 million by 2024. Each prisoner purchases two sets of uniforms every three years (the average prison term is about three years), and the total amount of fabric required is: (2 million / 3) x 2 sets x 3 meters / set = 4 million meters. It can be inferred from this that the use of fabrics (1) and (2) of the present invention can save procurement costs annually compared to existing prison uniform fabrics:

[0171] 4 million meters x [(2.6+3.3) / 2] yuan / meter = 2.95 yuan / meter x 4 million meters = 11.8 million yuan / year

[0172] (4) Existing defects: The existing prison uniforms are made of polyester filaments and have smooth surfaces. However, the fabric of the present invention is made of regenerated fibers through air-spinning, and its appearance, smoothness and flatness are not as good as those of the existing fabrics.

[0173] 12. The fabrics (1) and (2) of the present invention can also be used as sanitation work clothes. The only difference is the color.

[0174] Example 2: Security uniform fabrics (3) (4)

[0175] 1. Parameter comparison table of security clothing fabrics and alternative fabrics of the present invention:

[0176]

[0177] 2. The procurement and processing methods of raw materials are as described above.

[0178] 3. The proportion and arrangement order of spinning raw materials.

[0179] (1) Polyester colored fiber raw materials, accounting for 52% (Fabric 3) and 65% (Fabric 4) of the total input, all of which are black polyester fibers. During the input process, an additional 2% is added to the total amount.

[0180] (2) Pure cotton colored fiber; accounting for 48% and 63% (mixed colors) of the total input.

[0181] (3) The arrangement order is: one polyester and one cotton (fabric 3) and 1.3 coated and one cotton (fabric 4).

[0182] 4. The spinning method and process are as described above.

[0183] 5. Main spinning process parameters:

[0184]

[0185] 6. The weaving process is as described above.

[0186] 7. Warping process: Inventive fabric (3) 680 warp beams 10 warp beams per cylinder

[0187] Inventive fabric (4) 756 pieces / warp beam 10 warp beams / sizing per cylinder

[0188] 8. Sizing process: The sizing adopts "PVA + modified ingot powder", and its proportion / materials / auxiliaries and temperature and time are in accordance with conventional process parameters.

[0189] 9. Main weaving process parameters:

[0190] Project Name Fabric of the present invention (3) Fabric of the present invention (4) Total number of warps 6800 pieces (edge ​​yarn 48*2) 7560 pieces (edge ​​yarn 48*2) Reed 55.5#2 entry / reed 58#2 entry / reed fabric structure 2 / 2 left oblique 3 / 1 left oblique Weaving speed 600 rpm 600 rpm Reed width 70” 70” Reed width 66” 66” Finished product width 63” 63”

[0191] 10. Dyeing process: The process flow is the same as the above. The dyeing color is all black, the polyester colored fiber is all black, and the pure cotton part is all reactive black, and other trace active fuels are added to adjust the color.

[0192] 11. Compared with the low-end black security uniform fabrics (warp / weft yarns are all air-spun) currently produced on the market, the patented fabrics (3) and (4) of the present invention have the following social and economic benefits:

[0193] The low-end black security fabrics (warp and weft air yarns) currently sold on the market use brand-new polyester staple fibers (original white, 1.4-1.5D*38mm) produced by petrochemical industry as polyester raw materials. During the production process, a large amount of oil, energy and electric energy are consumed. In the dyeing process, high-temperature and high-pressure cationic dyes are used, which increases carbon emissions. However, the raw materials used in the fabrics (3) and (4) of the present invention are all recycled materials, and during the dyeing process, only 35%-50% of the cotton fibers are dyed. This process is a low-temperature and normal-pressure process, which consumes less dye and is environmentally friendly. It has the characteristics of being green, low-carbon and environmentally friendly.

[0194] There is a big price difference between the fabrics (3) (4) of the present invention and the low-end security clothing fabrics (3) (4) currently available on the market. According to the calculation results of the "parameter comparison table of security clothing fabrics and alternative fabrics of the present invention" in Example 2:

[0195] A: The price difference between the invented fabric (3) and the low-end security uniform fabric (3) currently available on the market is 2.3 yuan / m

[0196] B: The price difference between the invented fabric (4) and the low-end security clothing fabric (4) currently available on the market is 3 yuan / m

[0197] According to preliminary market forecasts: the total amount of low-grade security clothing fabrics (3) (4) sold in the national market each year is approximately more than 8 million meters. Based on this, it can be inferred that the security clothing fabrics (3) (4) of the present invention have huge direct economic benefits compared with the security clothing fabrics of the same grade sold in the existing market. The specific values ​​are:

[0198] 8 million meters * (3 + 2.3) / 2 yuan / meter = 21.2 million yuan / year

[0199] 12. Both low-quality security fabrics currently available on the market and the security clothing fabric of this invention are spun using air-end spinning, resulting in similar quality. However, due to the different raw materials used, the cost and appearance quality differ significantly. If color spots appear on the fabric during dyeing, they can be eliminated by applying 5g / L of cationic disperse dye and baking at high temperature.

[0200] Example 3: Takeaway and Express Delivery Autumn and Winter Clothing Fabrics (5)(6)

[0201] 1. Parameter comparison table of takeaway (express delivery) autumn and winter clothing fabrics and the alternative fabrics of the present invention:

[0202]

[0203] 2. The procurement and processing methods of the fabric (5) (6) of the present invention are as described above.

[0204] 3. Proportion and arrangement order of spinning raw materials:

[0205] (1) Polyester colored fiber raw materials account for 63% of the total input. Two types of polyester colored fiber recycled materials of similar colors are mixed, each accounting for about 31.5%. A total of 8-10 colors are purchased, and 4-5 colors of greige polyester are used. Then, pure cotton is used to adjust the color, and 10-20 different colors of fabrics can be produced. Pure cotton colored fiber raw materials account for 23%.

[0206] 4. The spinning method and process are as described above.

[0207] 5. Main spinning process parameters:

[0208]

[0209] 6. The weaving process is as described above.

[0210] 7. Warping process: Inventive fabric (5) 756 warps / beams 10 warp beams / sizing per cylinder

[0211] Inventive fabric (6) 630 pieces / warp beam 10 warp beams / sizing cylinder

[0212] 8. Sizing process: The sizing adopts "PVA + modified ingot powder", and its proportion / materials / auxiliaries and temperature and time are in accordance with conventional process parameters.

[0213] 9. Main weaving process parameters:

[0214] Project Name Fabric of the present invention (5) Fabric of the present invention (6) Total number of warps 7560 pieces (edge ​​yarn 48*2) 6300 pieces (edge ​​yarn 48*2) Reed 58#2 entry / reed 46#2 entry / reed fabric structure 3 / 1 left oblique 3 / 1 left oblique Weaving speed 600 rpm 600 rpm Reed width 70” 70” Reed width 66” 66” Finished product width 63” 63”

[0215] 10. Dyeing process: The process is the same as the above. Considering the autumn clothing fabrics and winter cotton-padded fabrics for express delivery (takeout), each piece of clothing is made up of 2-3 colors, mainly gray-blue as the main color. Other colors are based on customer requirements. First, the polyester fiber color (mixed) is selected, and then the color and luster of the pure cotton dyeing are adjusted with reactive dyes. In fact, this low-end professional fabric has less stringent requirements on color and luster. The fabric (6) is coated on the cloth surface to form a wind and rainproof function.

[0216] 11. Compared with the fabrics of the same grade and purpose currently produced on the market, the patented fabrics (5) and (6) of the present invention have the following social and economic benefits.

[0217] The polyester spinning raw material used in the professional workwear fabrics for express delivery / takeout currently sold on the market is a brand-new polyester chemical fiber (1.4-1.5D*38mm), which is a petrochemical product. During the fabric dyeing process, high-temperature and high-pressure cationic dyes are required, which will generate a large amount of energy consumption and carbon emissions. However, the fabrics (5) and (6) of the present invention all use recycled fibers and environmentally friendly reactive dyes, which are not only beneficial to the environment, but also reduce a large amount of energy consumption, and have obvious social benefits.

[0218] (2) There is a large price gap between the fabrics (5) (6) of the present invention and the corresponding fabrics (5) (6) currently available on the market. According to the calculation results of the "Parameter comparison table of takeaway and express autumn and winter clothing fabrics and the alternative fabrics (5) (6) of the present invention" in Example 3:

[0219] A: The price difference between the invented fabric (5) and the low-end security uniform fabric (5) currently available on the market is 4.4 yuan / m

[0220] B: The price difference between the invented fabric (6) and the low-end security clothing fabric (6) currently available on the market is 4.4 yuan / m

[0221] According to preliminary market forecasts, the total annual sales volume of this type of clothing fabrics (5) (6) in the national market is approximately 10 million meters, so the annual procurement cost can be saved:

[0222] 10 million meters / year*4.4 yuan / meter=44 million yuan / year

[0223] 12. The fabrics (5) and (6) of the present invention can be used as professional fabrics for other purposes besides autumn and winter clothing fabrics for takeout and express delivery.

[0224] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with this technology to understand the content of the present invention and implement it accordingly. In fact, in actual use, according to the season and the needs of different positions, the blending ratio of polyester and cotton, the thickness of yarn count, the warp and weft density of the weaving, the fabric structure, and the dyeing color will be changed into hundreds or even more than a thousand different varieties. In addition, the finished fabric can also be added with functional changes and effects such as coating, fire prevention, and cooling. However, these different varieties cannot limit the scope of protection of the present invention. Similar changes made according to the main points of the invention should be covered within the scope of protection of the present invention.

Claims

1. A process for producing professional workwear fabrics from recycled polyester and cotton fiber spinning materials, characterized in that: The steps include: a) opening and pretreating the dyed polyester recycled material and the dyed cotton recycled material to prepare spinnable fibers; b) using an air-spinning process to spin polyester-cotton or cotton-polyester blended yarn from the spinnable fiber; c) weaving the yarn into a grey fabric; d) dyeing the grey cloth; e) finishing the dyed grey cloth with an insoluble resin, wherein the insoluble resin contains a bio-based component and a nano-additive, and forming a coating through the steps of impregnation, pre-baking, calendering and curing.

2. The process for producing occupational workwear fabrics from recycled polyester and cotton fiber spinning materials according to claim 1 is characterized in that: The opening and pretreatment of the dyed polyester recycled material in step a) specifically includes: The polyester recycled material is opened by a single licker-in opener, and sprayed with an aqueous solution containing an antistatic agent to control the moisture regain at 2% to 3%; The mixture is allowed to stand for 36 to 48 hours to prepare spinnable polyester fibers.

3. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 1 is characterized in that: The opening and pretreatment of the colored cotton recycled material in step a) specifically includes: Cut the colored cotton recycled material into sections and stack them, spray them with an aqueous solution containing 0.05% to 0.1% swelling agent, and control the moisture regain to 8% to 9%; The fiber is opened through the waste yarn opening production line to control the main fiber length to 20-25 mm and the short fiber rate to be less than 30%.

4. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 1 is characterized in that: In step b), the air-spinning process specifically includes the following processes: cotton picking, heavy object separation, multi-bin cotton mixing, fine cotton opening, dust removal, carding, three-pass drawing, and air-spinning.

5. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 1 is characterized in that: The parameters of the spinning process in step b) include: The weight of the carded strip is 25-35g / 5m; The carding sliver delivery speed is 250-300m / min; The drawing speed is 600-700m / min; The rotor speed is 80,000 to 120,000 rpm, and the spinning speed is 120 to 150 m / min.

6. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 1 is characterized in that: The dyeing treatment in step d) specifically includes the following process: unwrapping and seaming of the grey cloth, singeing, soaking and cold rolling and standing, scouring and bleaching, mercerizing, and dyeing; wherein the soaking and cold rolling and standing step uses a solution containing 2 to 5 g / L of penetrant and 4 to 8 g / L of discoloring agent, and the cold rolling pressure is 0.1 to 0.2 MPa.

7. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 1 is characterized in that: The insoluble resin in step e) comprises the following components: by weight, 70% to 80% of modified polyurethane or water-based acrylic resin, 10% to 15% of bio-based polyol, 1% to 3% of nano-silicon oxide or nano-zinc oxide, 2% to 5% of a cross-linking agent, and the balance being an aqueous dispersant.

8. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 7 is characterized in that: In step e): The impregnation specifically includes: impregnating the dyed grey cloth in the insoluble resin solution with a concentration of 10% to 15% and a liquid squeeze rate of 60% to 80%; The pre-baking temperature is 80-100°C and the time is 2-3 minutes; The calendering temperature is 120-140°C and the pressure is 0.2-0.3 MPa; The curing adopts a staged curing method, first pre-curing at 100° C. for 30 seconds, and then curing at 150-180° C. for 1-2 minutes.

9. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 8, characterized in that: The impregnation is assisted by ultrasonic wave.

10. The process for producing occupational workwear fabrics from recycled colored polyester and colored cotton fiber spinning materials according to claim 7, characterized in that: The insoluble resin solution also contains 0.5% to 1% of a silicone softener.

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