High-efficiency processing technology for common carded cotton flax yarn-dyed fabric

Abstract

The invention relates to the technical field of weaving fabric processing technologies, and provides a high-efficiency common-carded cotton and linen yarn-dyed fabric processing technology which comprises the following steps: step 1, fiber pretreatment: mixing common-carded cotton fibers and linen fibers according to a mass ratio of 3: 1-5: 1, soaking the mixed fibers in a pretreatment solution which comprises 0.5-1.5% of bio-enzyme, 0.8-1.2% of hydrogen peroxide and 1-2% of a penetrant, controlling the pH value to be 8.5-9.5, controlling the temperature to be 85-100 DEG C, and keeping the temperature for 2-3 hours; the temperature is kept for 25-40 minutes, ultrasonic oscillation is carried out at the frequency of 20-30 Hz, and the fluctuation range of the liquid level is 5-10 mm; the pretreated fibers are treated through a high-speed opener, the rotating speed of the opener ranges from 800 r / min to 1200 r / min, and the needle tooth density of a needle roller ranges from 50 teeth / cm to 80 teeth / cm. The appearance, the hand feeling and the dyeing uniformity of the yarn-dyed fabric are improved through the specific proportion of the common carded cotton and the linen fibers and fine treatment; by means of a tension self-adaption system, a humidity sensor and the like, the defective rate and faults are reduced, efficiency is improved, optical detection and image recognition are combined, and stable product quality is guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of weaving processing technology, in particular to a high-efficiency carded cotton and linen yarn-dyed weaving technology. Background Art

[0002] In the textile industry, yarn-dyed fabrics, with their rich colors and diverse patterns, are widely used in clothing, home textiles, decoration, and other fields, and are highly favored by consumers. With the improvement of people's living standards and the continuous upgrading of aesthetic demands, the market has put forward higher requirements for the appearance quality, hand comfort, and dyeing uniformity of yarn-dyed fabrics, and has also imposed stricter standards for efficiency, stability, and product quality control during the production process.

[0003] Current processing techniques for carded cotton and linen yarn-dyed fabrics have significant limitations. During fiber pretreatment, traditional processes often rely on a single chemical agent, which is incapable of completely breaking down impurities such as pectin and wax on the fiber surface. The lack of physical aids results in poor fiber permeability, preventing uniform dye adhesion during subsequent dyeing, leading to color variations and color fringing. During fiber blending and opening, conventional opening equipment lacks precise control over fiber length uniformity and impurity removal. Improper needle roller configuration can easily lead to fiber damage or inadequate opening, compromising the fabric's feel and strength. During dyeing, most companies use a fixed temperature method, which fails to adapt to the reactive dye's reactivity with the fiber at different stages, resulting in low dye utilization and poor color fastness. During weaving, traditional looms rely on manual control of warp tension, making it difficult to adapt to dynamic changes during production. This frequently results in fabric defects such as loose edges and weft skew. During finishing, the drying process lacks precise humidity monitoring and control, which can lead to overdrying or uneven drying of the fabric, increasing the defect rate. In terms of quality inspection, manual visual inspection is inefficient and subject to large errors, making it difficult to meet the demand for rapid and accurate product quality screening in large-scale production. Therefore, it is urgent to develop a processing technology for carded cotton and linen yarn-dyed fabrics that can achieve efficient production and significantly improve product quality. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the present invention provides a high-efficiency carded cotton and linen yarn-dyed fabric processing technology, which solves the problems of low efficiency and poor quality in multiple links such as pretreatment and dyeing in the existing technology.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: A high-efficiency carded cotton and linen yarn-dyed fabric processing process, comprising the following steps: Step 1, fiber pretreatment: carded cotton fiber and flax fiber are mixed in a mass ratio of 3:1 to 5:1, and immersed in a pretreatment solution containing 0.5% to 1.5% biological enzyme, 0.8% to 1.2% hydrogen peroxide, 1% to 2% penetrant, and a pH value of 8.5 to 9.5. The temperature is controlled at 85°C to 100°C, and the temperature is kept for 25 to 40 minutes. Ultrasonic vibration is applied at a frequency of 20 to 30 Hz, and the liquid level fluctuation amplitude is 5 to 10 mm; Step 2: Fiber mixing and opening: The pretreated fibers are processed by a high-speed opening machine with a speed of 800-1200 r / min, a needle roller tooth density of 50-80 teeth / cm², and a negative pressure adsorption module adsorption pressure of -0.05-0.1 MPa. The fiber length uniformity after opening is ≥90%; Step 3: Dyeing: Use reactive dyes for dyeing, with a dye concentration of 3% to 8%, add 0.2 to 0.5 g / L of leveling agent and 1 to 2 g / L of pH buffer, and use a stepwise heating method: the initial temperature is 30°C, raised to 60°C at 2°C / min, and then raised to 80°C at 1°C / min, and kept at this temperature for 30 to 50 minutes; Step 4: Weaving and forming: The dyed fibers are woven through a rapier loom with a warp density of 80 to 120 yarns per inch and a weft density of 60 to 100 yarns per inch. The rapier loom is equipped with a tension adaptive system, and the warp tension fluctuation range is ≤5%; Step 5, microwave assisted finishing: high-pressure steam setting (0.3-0.5 MPa, 10-15 min), circulating water washing (10-15 MPa) and microwave drying (power 5-10 kW, time 3-8 min) are carried out in sequence. The microwave power P (kW) and moisture content W (%) satisfy P = 0.8W + 2 (5 ≤ W ≤ 15); Step 6. Inspection and repackaging: Finished products with a color difference of ΔE ≤ 1.0 are screened by an optical detector using multi-spectral imaging technology with a detection wavelength range of 400-700nm and a resolution of ≤0.1mm, and then cut into rolls.

[0006] Preferably, the temperature of the dye liquor in the dyeing treatment in step 3 is controlled at 60° C. to 80° C., and a device for circulating and filtering the dye liquor is provided, the device comprising a filter and a circulation pump, and the filtration accuracy of the filter is 5 μm to 10 μm.

[0007] Preferably, the microwave drying device in step five includes: a microwave emission unit with a frequency of 2450 MHz ± 50 MHz; a conveyor belt with a surface covered with a high-temperature resistant ceramic coating and an adjustable conveying speed range of 0.5 to 2 m / min; and a humidity sensor for real-time monitoring of the moisture content of the fabric and feeding back to the control terminal.

[0008] Preferably, after the high-speed opener removes fiber impurities in step 2, the fiber impurity content is ≤0.5%.

[0009] Preferably, the grey cloth woven in the step 4 needs to be pre-shaped before the step 5, and is subjected to wet heat setting by a first setting machine, the temperature of which is controlled at 110-130°C, and the hair balls are removed by a shaving assembly, which includes an upper pressing roller, a lower pressing roller and a corresponding razor, the pore density of the roller surface is 10-15 / cm², and the internal air cavity pressure is 0.2-0.4MPa.

[0010] Preferably, the post-processing in step five further includes softening the grey cloth by using a softener spraying device and a roller, wherein the spraying amount of the softener is 10 g / m²−20 g / m², and the softener is an organosilicon compound with a hydrogen content of 0.15% to 0.25%.

[0011] Preferably, in the step 6 of inspecting and packaging, an image recognition system is used to assist in detecting dyeing defects. The resolution of the image recognition system is ≥500DPI, and the detection efficiency is improved by 60% to 80% compared with manual detection.

[0012] Preferably, 3% to 6% of a brightener may be added to the pretreatment liquid in step 1.

[0013] Preferably, the pretreatment unit comprises a stirring device, an overflow cleaning tank, and an ultrasonic oscillation device; Opening unit: including a high-speed opener, which includes multiple sets of needle rollers and a negative pressure adsorption module; Dyeing unit: Contains dye vat, continuous steamer, and the dye vat is equipped with a pushing mechanism and an air blowing mechanism; Weaving unit: including rapier loom with tension adaptive system; Finishing unit: including steam setting machine, high-pressure water washing equipment, microwave drying device, microwave drying device including microwave emission unit, conveyor belt, humidity sensor; Detection unit: includes optical detector and image recognition system.

[0014] Preferably, the high-pressure water washing equipment adopts a circulating water system and is provided with a biodegradation agent adding device; the steam setting machine adopts high-pressure saturated steam with a steam pressure of 0.3 to 0.5 MPa.

[0015] The present invention provides a highly efficient carded cotton and linen yarn-dyed fabric processing process, which has the following beneficial effects: 1. The present invention mixes carded cotton and flax fibers in a specific ratio and adopts a series of refined processing steps, such as soaking in a pretreatment liquid containing biological enzymes, hydrogen peroxide and other ingredients combined with ultrasonic vibration in fiber pretreatment, high-speed opener treatment for fiber mixing and opening, reactive dyeing with segmented temperature increase, and microwave-assisted post-finishing, so that the final processed yarn-dyed fabric is significantly improved in appearance, feel, dyeing uniformity and other aspects.

[0016] 2. This invention utilizes a rapier loom's adaptive tension system and a microwave drying unit's humidity sensor and control system to effectively reduce defective product rates and production failures during the production process, thereby improving production efficiency. Furthermore, the use of an optical detector and image recognition system enables rapid and accurate detection of color differences and dyeing defects in fabrics, allowing for the timely screening of substandard products and further ensuring the stability of product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a process flow chart of the present invention; Figure 2 is a system diagram of the pre-processing unit of the present invention; Figure 3 is a system diagram of the opening unit of the present invention; Figure 4 is a system diagram of the dyeing unit of the present invention; Figure 5 is a system diagram of a weaving unit of the present invention; Figure 6 It is a system diagram of the finishing unit of the present invention; Figure 7 It is a system diagram of the detection unit of the present invention. DETAILED DESCRIPTION

[0018] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention. Example

[0019] Please see the attached Figure 1 -Attached Figure 3 The embodiment of the present invention provides a high-efficiency carded cotton and linen yarn-dyed fabric processing process, comprising the following steps: Step 1. Mix the carded cotton fiber and flax fiber in a mass ratio of 4:1 and soak them in the pretreatment liquid. The main components of the pretreatment liquid include biological enzymes (1.0%), hydrogen peroxide (1.0%), and penetrant (1.5%). The pH value needs to be adjusted to 9.0 to create a weak alkaline environment to promote the decomposition of impurities on the fiber surface and the activity of enzymes. The temperature is controlled at 95°C and kept warm for 30 minutes. During this process, the biological enzyme can catalyze the decomposition of impurities such as pectin and wax on the fiber surface, hydrogen peroxide has a bleaching effect, and the penetrant helps the agent penetrate into the fiber to improve the treatment effect. At the same time, ultrasonic oscillation is performed at a frequency of 25Hz to keep the liquid level fluctuation amplitude at 8mm. The cavitation effect of the ultrasonic wave can further destroy the impurity structure and accelerate the pretreatment process. According to actual needs, 4% of whitening agent can also be added to the pretreatment liquid to improve the whiteness of the fiber. After the treatment is completed, the fiber is taken out and rinsed thoroughly with clean water to remove residual agents; Step 2: Feed the pretreated fibers into a high-speed opening machine. The speed of the opening machine is set to 1000r / min, and the needle roller needle tooth density is controlled at 60 teeth / cm². The fiber bundles are decomposed into single fibers by the tearing and combing action between the needle teeth. The adsorption pressure of the negative pressure adsorption module is maintained at -0.08MPa. Impurities and short fibers generated during the opening process are adsorbed and removed by negative pressure to ensure that the fiber impurity content after opening is ≤0.4%. During the opening process, the fiber length uniformity is monitored in real time to ensure that it is 92%, providing fiber raw materials with stable quality for subsequent processing. After the opening is completed, the fibers are collected and temporarily stored in a clean container; Step 3: Dye the opened fibers with reactive dyes at a concentration of 5%, precisely adjusted according to the desired color depth and fiber quality. A leveling agent (0.3 g / L) and a pH buffer (1.5 g / L) are added to the dye liquor. The leveling agent ensures uniform dye absorption and prevents color bleeding, while the pH buffer maintains a stable pH value, ensuring optimal dyeing. A stepwise heating method is used: the initial temperature is set at 30°C and then increased at a rate of 2°C / min to 60°C to allow the fibers to gradually adapt to the temperature change and promote slow dye absorption. The temperature is then increased at a rate of 1°C / min to 80°C and maintained at this temperature for 40 minutes to ensure a thorough chemical reaction between the dye and the fiber, improving color fastness. The dye liquor temperature is maintained at 80°C throughout the entire process. Simultaneously, the dye liquor is circulated and filtered using a dye liquor recirculation filtration device (including an 8μm filter and a circulation pump) to promptly remove impurities and unreacted dye particles from the dye liquor, preventing them from adhering to the fiber surface and affecting dyeing quality. After dyeing, the fibers are taken out and subjected to post-treatment such as washing and soaping to remove loose colors; Step 4. The dyed fibers are woven through a rapier loom. The warp density is set to 100 yarns / inch and the weft density is set to 80 yarns / inch, which are precisely adjusted according to the fabric specifications. The rapier loom is equipped with a tension adaptive system to monitor and adjust the warp tension in real time to ensure that the warp tension fluctuation range is ≤4%, avoiding defects such as loose edges and weft skew in the fabric due to uneven tension. Before weaving, the grey fabric is pre-shaped and wet-heat shaped through the first setting machine. The temperature is controlled at 120°C. The wet-heat effect stabilizes the fiber structure and improves the dimensional stability of the fabric. At the same time, a shaving assembly is used to remove lint. The shaving assembly consists of an upper pressing roller, a lower pressing roller and a corresponding razor. The pore density of the roller surface is 12 / cm² and the internal air cavity pressure is 0.3MPa. The lint is adsorbed to the roller surface by air pressure and then shaved off by the razor to make the fabric surface smooth and clean. After the pre-setting is completed, formal weaving is carried out to weave grey fabric that meets the requirements; Step 5: Microwave-assisted finishing: The woven fabric is placed in a steam setting machine and subjected to high-pressure saturated steam at a pressure of 0.4 MPa for 12 minutes. The high temperature and high pressure of the steam further stabilize the fabric structure, improving its feel and dimensional stability. Circulating water washing: A high-pressure water washing machine is used for circulating water washing at a pressure of 12 MPa. The high-pressure water flow rinses the fabric to remove impurities and additives remaining on the surface. The high-pressure water washing machine uses a circulating water system and is equipped with a biodegradable agent addition device to preliminarily treat the washing wastewater and reduce pollutant emissions. Microwave drying: The washed fabric is fed into a microwave drying unit. The microwave transmission unit frequency is 2450 MHz ± 50 MHz, and the conveyor belt surface is covered with a high-temperature resistant ceramic coating. The conveyor speed is adjustable within a range of 1 m / min. The microwave power is adjusted in real time based on the fabric moisture content, according to the relationship between microwave power (P (kW)) and moisture content (W (%)) (P = 0.8W + 2 (5 ≤ W ≤ 15)), achieving efficient and energy-saving drying. During the drying process, the humidity sensor monitors the moisture content of the fabric in real time and feeds back to the control terminal to ensure that the fabric is dried evenly and meets the specified moisture content requirements. Softening treatment: After drying, the grey fabric is softened. A softener spray device and rollers are used to evenly spray a 0.2% hydrogen-containing silicone softener at a spray rate of 15g / m² onto the fabric surface. The softener is then pressed with rollers to fully penetrate the fabric, improving the fabric's feel and making it soft and smooth. Step 6: Use an optical detector to detect color difference on the finished fabric. The optical detector uses multispectral imaging technology with a detection wavelength range of 400-700nm and a resolution of 0.08mm to screen out finished products with a color difference ΔE ≤ 1.0. At the same time, an image recognition system is used to assist in the detection of dyeing defects. The image recognition system has a resolution of 600DPI, which is 70% more efficient than manual inspection. It can quickly and accurately identify defects such as color spots, color stripes, and color flowers on the fabric surface. Qualified fabrics are cut into rolls according to the specified size and packaged for storage; Please see the attached Figure 4 -Attached Figure 7 , opening unit: including high-speed opener, which includes multiple sets of needle rollers and negative pressure adsorption modules; Dyeing unit: Contains dye vat, continuous steamer, and the dye vat is equipped with a pushing mechanism and an air blowing mechanism; Weaving unit: including rapier loom with tension adaptive system; Finishing unit: includes steam setting machine, high-pressure water washing equipment, microwave drying device. The microwave drying device includes a microwave emission unit, a conveyor belt, and a humidity sensor. The high-pressure water washing equipment adopts a circulating water system and is equipped with a biodegradation agent addition device. The steam setting machine uses high-pressure saturated steam with a steam pressure of 0.3-0.5MPa. Detection unit: includes optical detector and image recognition system.

[0020] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A high-efficiency carded cotton and linen yarn-dyed fabric processing process, characterized in that: The following steps are involved: Step 1, fiber pretreatment: carded cotton fiber and flax fiber are mixed in a mass ratio of 3:1 to 5:1, and immersed in a pretreatment solution containing 0.5% to 1.5% biological enzyme, 0.8% to 1.2% hydrogen peroxide, 1% to 2% penetrant, and a pH value of 8.5 to 9.

5. The temperature is controlled at 85°C to 100°C, and the temperature is kept for 25 to 40 minutes. Ultrasonic vibration is applied at a frequency of 20 to 30 Hz, and the liquid level fluctuation amplitude is 5 to 10 mm; Step 2: Fiber mixing and opening: The pretreated fibers are processed by a high-speed opening machine with a speed of 800-1200 r / min, a needle roller tooth density of 50-80 teeth / cm², and a negative pressure adsorption module adsorption pressure of -0.05-0.1 MPa. The fiber length uniformity after opening is ≥90%; Step 3: Dyeing: Use reactive dyes for dyeing, with a dye concentration of 3% to 8%, add 0.2 to 0.5 g / L of leveling agent and 1 to 2 g / L of pH buffer, and use a stepwise heating method: the initial temperature is 30°C, raised to 60°C at 2°C / min, and then raised to 80°C at 1°C / min, and kept at this temperature for 30 to 50 minutes; Step 4: Weaving and forming: The dyed fibers are woven through a rapier loom with a warp density of 80 to 120 yarns per inch and a weft density of 60 to 100 yarns per inch. The rapier loom is equipped with a tension adaptive system, and the warp tension fluctuation range is ≤5%; Step 5, microwave assisted finishing: high-pressure steam setting (0.3-0.5 MPa, 10-15 min), circulating water washing (10-15 MPa) and microwave drying (power 5-10 kW, time 3-8 min) are carried out in sequence. The microwave power P (kW) and moisture content W (%) satisfy P = 0.8W + 2 (5 ≤ W ≤ 15); Step 6. Inspection and repackaging: Finished products with a color difference of ΔE ≤ 1.0 are screened by an optical detector using multi-spectral imaging technology with a detection wavelength range of 400-700nm and a resolution of ≤0.1mm, and then cut into rolls.

2. The high-efficiency carded cotton and linen yarn-dyed fabric processing process according to claim 1, characterized in that: The temperature of the dye liquor in the dyeing treatment in step 3 is controlled at 60° C. to 80° C., and a device for circulating and filtering the dye liquor is provided. The device includes a filter and a circulation pump, and the filtration accuracy of the filter is 5 μm to 10 μm.

3. The high-efficiency carded cotton and linen yarn-dyed fabric processing process according to claim 1, characterized in that: The microwave drying device in step 5 includes: a microwave transmitting unit with a frequency of 2450 MHz ± 50 MHz; a conveyor belt with a surface covered with a high-temperature resistant ceramic coating and an adjustable conveying speed range of 0.5 to 2 m / min; and a humidity sensor for real-time monitoring of the moisture content of the fabric and feeding back to the control terminal.

4. The high-efficiency carded cotton and linen yarn-dyed fabric processing process according to claim 1, characterized in that: After the high-speed opening machine removes fiber impurities in the step 2, the fiber impurity content is ≤0.5%.

5. The high-efficiency carded cotton and linen yarn-dyed fabric processing process according to claim 1, characterized in that: The grey fabric woven in step 4 needs to be pre-shaped before step 5, and is subjected to wet heat setting by a first setting machine, with the temperature controlled at 110-130°C. At the same time, the hair balls are removed by a shaving assembly, which includes an upper pressing roller, a lower pressing roller and a corresponding razor. The pore density on the roller surface is 10-15 / cm², and the internal air cavity pressure is 0.2-0.4MPa.

6. The high-efficiency carded cotton and linen yarn-dyed fabric processing process according to claim 1, characterized in that: The post-processing in step 5 also includes softening the grey cloth using a softener spraying device and a roller. The spraying amount of the softener is 10g / m²−20g / m². The softener is an organic silicon compound with a hydrogen content of 0.15% to 0.25%.

7. The high-efficiency carded cotton and linen yarn-dyed fabric processing process according to claim 1, characterized in that: In the step 6 inspection and packaging, an image recognition system is used to assist in detecting dyeing defects. The image recognition system has a resolution of ≥500DPI, and the detection efficiency is improved by 60% to 80% compared with manual inspection.

8. The high-efficiency carded cotton and linen yarn-dyed fabric processing process according to claim 1, characterized in that: A whitening agent of 3% to 6% may be added to the pretreatment liquid in step 1.

9. A system for processing high-efficiency carded cotton and flax yarn-dyed fabrics, using the high-efficiency carded cotton and flax yarn-dyed fabric processing process according to any one of claims 1 to 8, characterized in that: The following steps are involved: Pretreatment unit: including stirring device, overflow cleaning tank, and ultrasonic oscillation device; Opening unit: including a high-speed opener, which includes multiple sets of needle rollers and a negative pressure adsorption module; Dyeing unit: Contains dye vat, continuous steamer, and the dye vat is equipped with a pushing mechanism and an air blowing mechanism; Weaving unit: including rapier loom with tension adaptive system; Finishing unit: including steam setting machine, high-pressure water washing equipment, microwave drying device, microwave drying device including microwave emission unit, conveyor belt, humidity sensor; Detection unit: includes optical detector and image recognition system.

10. The system for processing high-efficiency carded cotton and linen yarn-dyed fabrics according to claim 9, characterized in that: The high-pressure water washing equipment adopts a circulating water system and is provided with a biodegradation agent adding device; the steam setting machine adopts high-pressure saturated steam with a steam pressure of 0.3-0.5 MPa.

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