Efficient carding method for worsted wool fabric

Abstract

The invention relates to the technical field of worsted wool fabric industry, and discloses an efficient carding method of worsted wool fabric, which comprises the following steps: sequentially degreasing wool fibers, removing impurities, improving the surface performance of the fibers, and preparing for subsequent processing; the pretreated wool fibers are subjected to modification treatment, and the fiber characteristics are changed in the aspects of chemistry, physics and machinery; the modified wool fibers are subjected to anti-yellowing treatment, so that the fibers are prevented from yellowing in the subsequent processing and using processes; and carrying out antistatic treatment on the wool fibers subjected to the anti-yellowing treatment. The attractiveness, comfort, durability and market competitiveness of the product are comprehensively enhanced by improving the cleanliness and activity of the fibers, preventing yellowing, resisting static electricity, optimizing the dyeing process, performing after-treatment, monitoring and detecting the quality in the whole process and the like, and the requirements of the market and consumers are met. The problem that the comprehensive performance of wool fibers cannot meet the high-quality requirement of wool worsted fabric products is solved.

Description

Technical Field

[0001] This invention relates to the technical field of worsted wool fabric industry, specifically to an efficient combing method for worsted wool fabric. Background Technology

[0002] In the production of worsted wool fabrics, wool fiber is a key raw material, but its overall performance often fails to meet the requirements for high-quality products.

[0003] Fabrics made from untreated wool fibers typically have a rough feel, causing itching when worn and offering poor skin-friendliness. Furthermore, wool fibers are prone to shrinkage and deformation during routine washing, leading to changes in garment size and affecting fit and appearance upon re-wearing. These performance defects make these products less appealing to consumers and fail to meet modern consumers' high-quality demands for comfortable and easy-care worsted wool products. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the present invention provides an efficient combing method for worsted wool fabrics, which solves the problem that the comprehensive properties of wool fibers are difficult to meet the high-quality requirements of worsted wool fabric products.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a highly efficient carding method for worsted wool fabrics, comprising the following steps:

[0006] S1. The wool fibers are degreased sequentially to remove impurities and improve the surface properties of the fibers in preparation for subsequent processing.

[0007] S2. Modify the pretreated wool fibers to change their properties from chemical, physical and mechanical aspects.

[0008] S3. Carry out anti-yellowing treatment on the modified wool fibers to prevent yellowing during subsequent processing and use;

[0009] S4. Antistatic treatment is applied to wool fibers after anti-yellowing treatment.

[0010] S5. Optimize the dyeing process for fibers that have undergone antistatic treatment;

[0011] S6. Perform finishing treatment on the dyed fibers;

[0012] S7. Implement quality monitoring throughout the entire production process of worsted wool fabrics and conduct comprehensive testing on the finished products.

[0013] By adopting the above technical solutions, each step of the efficient combing method for worsted wool fabrics is beneficial: degreasing treatment aids subsequent processing, modification treatment optimizes fiber characteristics, anti-yellowing treatment preserves color, antistatic treatment improves comfort, dyeing optimization enables efficient dyeing, finishing improves ease of use, and quality monitoring and testing stabilize quality, thus comprehensively improving product quality and competitiveness and promoting industrial development.

[0014] Preferably, step S1 specifically includes: using an acetone solution for degreasing, controlling the treatment temperature at 28-32°C, and treating for about 2 hours; at this temperature and duration, the concentration of the acetone solution is maintained at 80%, which can fully remove the grease from the surface of the wool fibers, and the oil content of the fibers after treatment is reduced to below 0.5%, creating favorable conditions for subsequent treatment and allowing subsequent chemical reagents to come into more sufficient contact with the fibers.

[0015] Preferably, S2 specifically includes: the concentration of the hydroxyl and carboxyl compound reagent used in the chemical modification is 8%, the reaction temperature is precisely controlled at 60°C, and the reaction time is set to 2.5 hours; after this treatment, the number of hydrophilic groups on the fiber surface increases by about 30%, the moisture absorption rate is increased to about 15% compared with the untreated state, and the color difference during dyeing can be controlled within ΔE*≤1.5.

[0016] Preferably, step S3 specifically includes: the preparation of the anti-yellowing solution involves adding 0.4-0.5 kg of lemon juice to 10 kg of deionized water, heating and boiling to 92-95°C, and then adding 0.35-0.45 kg of skim milk. The fiber is soaked for about 4 hours. After this operation, a protective film with a thickness of about 50-80 nm is formed on the fiber surface. After 100 hours of accelerated aging test, the yellowing index does not increase by more than 5.

[0017] Preferably, step S4 specifically includes: when preparing the pretreatment solution, the amount of reducing agent is 10% based on the weight of the wool fibers, the amount of thioctic acid is 2%, and the pH value is strictly adjusted to 8.5; after the fibers are immersed in the pretreatment solution and heated to 60°C and kept at that temperature for 2 hours, the surface resistivity of the fibers decreases from the original 10... 13 Ω drops to 10 8 -10 9 Ω, the electrostatic voltage generated by friction can be controlled within 500V, and the electrostatic half-life is shortened to about 3 seconds.

[0018] Preferably, step S5 specifically includes: controlling the initial dyeing temperature at 42-48℃ for about 40 minutes, then increasing the temperature to 85℃ at a rate of 1℃ / minute, with a total dyeing time of about 2 hours, while stabilizing the pH value of the dyeing bath at about 5; through this segmented temperature dyeing process, the dye uptake rate reaches more than 90%.

[0019] Preferably, step S6 specifically includes: softening finishing using a 5% concentration of silicone softener solution, soaking the fibers for 30 minutes at 25°C, and controlling the pick-up rate at around 90%; after this treatment, the bending stiffness of the fabric is reduced by about 40% compared to before treatment, the surface friction coefficient is reduced to 0.2-0.3, and according to the five-level hand feel rating system, the hand feel score can be improved to more than 4 points.

[0020] Preferably, S7 specifically includes: in the physical performance test of the finished product, the tensile strength needs to reach 350-450N, the tear strength needs to reach 20-25N, the air permeability needs to reach 150-250mm / s, the bursting strength needs to reach 300-400N, and the elongation at break needs to be controlled between 30% and 40%.

[0021] Preferably, S7 further includes: in the chemical performance test of the finished product, the pH value must be between 5 and 7, the formaldehyde content must be strictly limited to below 75 mg / kg, the content of decomposed aromatic amine dyes must not exceed 20 mg / kg, and all color fastness indicators must reach level 4 or above.

[0022] Working Principle: First, degreasing treatment uses organic solvents or reagents to remove impurities based on the principle of "like dissolves like" and chemical reactions, thereby enhancing fiber surface activity. Modification treatment addresses the issue from chemical, physical, and mechanical perspectives. Chemical modification introduces functional groups to alter chemical properties, physical modification adjusts the internal structure, and mechanical modification optimizes fiber morphology. Anti-yellowing treatment relies on solutions containing antioxidants and film-forming substances, which adhere to the fibers through soaking and other processes, inhibiting oxidation and external factors. Antistatic treatment uses antistatic agents to adsorb or chemically modify the fibers to introduce conductive functional groups, reducing surface resistance. Dyeing process optimization utilizes segmented heating, pH control, and selection of suitable dyes and auxiliaries to promote uniform dye adsorption and binding. Finishing uses auxiliaries to form a film on the fiber surface, improving wearing performance. Quality monitoring and finished product testing involve real-time monitoring of equipment at each stage, performing physical and chemical property tests on the finished product, adjusting and judging according to standards to ensure stable quality. Each step synergistically enhances the overall performance of wool fibers, meeting the requirements for worsted wool fabric production.

[0023] This invention provides a highly efficient carding method for worsted wool fabrics. It has the following beneficial effects:

[0024] 1. This invention comprehensively enhances the aesthetics, comfort, durability, and market competitiveness of products by improving fiber cleanliness and activity, multi-dimensional modification, anti-yellowing, antistatic properties, optimizing dyeing processes, finishing, and full-process quality monitoring and testing, thus meeting market and consumer demands. It solves the problem that the overall performance of wool fibers is insufficient to meet the high-quality requirements of worsted wool fabric products.

[0025] 2. This invention uses acetone solution to degrease wool fibers, maintaining a temperature of 28-32℃ for about 2 hours to keep the concentration at 80%. Through temperature, stirring, concentration monitoring and replenishment mechanisms, the oil content is reduced to below 0.5% to meet the standard, the impurity coverage is greatly reduced, the fiber reactivity is enhanced, the reagent utilization rate is increased by about 25%, and the chemical treatment time is reduced by about 30%, thereby improving the quality and efficiency of subsequent processing, solving the problems of traditional water washing degreasing, and contributing to industrial environmental protection and economic development.

[0026] 3. This invention uses a specific ratio to prepare an anti-yellowing solution, which, after heating and soaking, forms a 50-80nm thick protective film on the fiber surface. In a 100-hour accelerated aging test, the yellowing index increases by no more than 5, thus delaying fiber yellowing, improving the stability of product appearance quality, and solving the problem of wool fibers easily turning yellow.

[0027] 4. This invention employs a segmented temperature dyeing process, controlling the initial dyeing temperature at 42-48℃ for approximately 40 minutes, then gradually increasing it to 85℃ at a rate of 1℃ / minute and maintaining this temperature for approximately 2 hours. Simultaneously, the pH value of the dyeing bath is stabilized at around 5. This achieves a dye uptake rate of over 90%, resulting in full, uniform fiber dyeing and enhancing the product's aesthetics and competitiveness. It solves the problems of uneven dyeing, color differences, and uneven color distribution found in traditional dyeing processes.

[0028] 5. This invention establishes quality monitoring and comprehensive finished product testing throughout the entire production process of worsted wool fabrics. It specifies detailed ranges for physical properties such as tensile strength, tear strength, air permeability, and elongation at break, as well as chemical properties including pH, formaldehyde content, and color fastness requirements. This ensures stable product quality, compliance with relevant standards, and enhances market competitiveness and brand image. It solves the problem of quality fluctuations and inconsistent product quality caused by multiple factors during production. Attached Figure Description

[0029] Figure 1 This is a flowchart of the efficient carding method for worsted wool fabrics proposed in this invention. Detailed Implementation

[0030] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Please see the appendix Figure 1 This invention provides a highly efficient carding method for worsted wool fabrics, comprising the following steps:

[0032] S1. The wool fibers are degreased sequentially to remove impurities and improve the surface properties of the fibers, in preparation for subsequent processing.

[0033] Specifically, S1 includes: degreasing treatment using acetone solution, with the treatment temperature controlled at 28-32℃ and the treatment time at about 2 hours; at this temperature and duration, the acetone solution concentration is maintained at 80%, which can fully remove the grease from the surface of the wool fibers, and the oil content of the fibers after treatment is reduced to below 0.5%, creating good conditions for subsequent treatment and allowing the subsequent chemical reagents to come into more thorough contact with the fibers.

[0034] Specifically, in its natural state, wool fibers are covered with a layer of grease, a mixture of lanolin, free fatty acids, and some impurities. This grease layer can hinder many subsequent processing steps. The acetone solution used in degreasing removes the grease from the surface of wool fibers based on the principle of "like dissolves like" as an organic solvent.

[0035] Specifically, within the set temperature range of 28-32℃, molecular thermal motion becomes more active as the temperature increases. For acetone molecules, within this temperature range, they can penetrate more efficiently into the internal structure of the oil molecules on the surface of wool fibers with suitable kinetic energy. There is a physical adsorption force between the oil molecules and the fiber, and acetone molecules, through their interaction with the oil molecules, gradually disrupt this adsorption relationship, causing the oil molecules to gradually dissociate from the fiber surface.

[0036] The processing time was set at approximately 2 hours, an optimal duration determined through extensive experimental verification. Within this timeframe, the acetone solution can fully contact the oils on the surface of the wool fibers, ensuring sufficient time for oil molecules to diffuse from the fiber surface into the acetone solution. Furthermore, maintaining an 80% acetone solution concentration is the optimal value determined after comprehensively considering its oil-dissolving ability and its impact on the fiber structure. Too high a concentration may damage some internal fiber structures due to excessive swelling; while too low a concentration will not effectively dissolve and remove the oils from the wool fiber surface.

[0037] Throughout the degreasing process, several key physical processes are involved to enhance the degreasing effect. For example, the mixture of fiber and acetone solution is stirred using a stirring device at a speed controlled at 120-150 rpm. This stirring speed creates turbulence in the solution system, greatly promoting mass transfer efficiency and ensuring more thorough and uniform contact between acetone molecules and oil molecules. This, in turn, accelerates the rate of oil dissolution, increasing the dissolution rate by approximately 30% compared to no stirring or low stirring speed.

[0038] Meanwhile, to ensure the stability of the acetone solution concentration, a concentration monitoring and automatic replenishment mechanism is employed. Every 30 minutes, the acetone solution concentration is detected using a high-precision densitometer. If a decrease in concentration is detected, pure acetone is added to the solution via an automated replenishment system, thus maintaining a constant concentration of 80%, ensuring the stability and reliability of the entire degreasing process. Furthermore, temperature control is also crucial. Utilizing a PID intelligent temperature control system, the fluctuation range of the processing temperature can be precisely controlled within ≤±0.5℃. This is because when the temperature exceeds 35℃, the evaporation rate of acetone increases significantly (approximately by 50%), which not only wastes acetone but may also affect the degreasing effect due to rapid changes in solution concentration. Therefore, strict temperature control is essential to ensuring the effectiveness of the degreasing process.

[0039] By using acetone solution to degrease wool fibers, maintaining a temperature of 28-32℃ for approximately 2 hours and keeping the acetone concentration at 80%, and through precise temperature control, appropriate stirring rate, and a concentration monitoring and replenishment mechanism, several beneficial effects were achieved. The oil content could be stably reduced to below 0.5%, meeting industry standards. Surface impurity coverage was significantly reduced, and the exposure of polar groups on the fiber surface enhanced reactivity. Simultaneously, reagent utilization increased by approximately 25%, and chemical treatment time was shortened by approximately 30%. This lays the foundation for efficient and low-consumption processing of worsted wool fabrics, comprehensively improving subsequent processing quality and production efficiency, and contributing to the industry's development towards environmental protection and economic efficiency. It also solves the problems of uneven pretreatment and large fluctuations in oil content associated with traditional water washing and degreasing pretreatment.

[0040] S2. Modify the pretreated wool fibers by changing their properties chemically, physically and mechanically.

[0041] S2 specifically includes: the concentration of hydroxyl and carboxyl compounds used in chemical modification is 8%, the reaction temperature is precisely controlled at 60℃, and the reaction time is set to 2.5 hours; after this treatment, the number of hydrophilic groups on the fiber surface increases by about 30%, the moisture absorption rate is increased to about 15% compared with the untreated state, and the color difference during dyeing can be controlled within ΔE*≤1.5.

[0042] Specifically, in the chemical modification process, compounds containing hydroxyl and carboxyl groups are selected as modifying agents, with a concentration set at 8%. This concentration was determined through multiple experimental screenings to ensure the modification effect while avoiding adverse effects on the fibers due to excessive or insufficient reagent. The reaction temperature is precisely controlled at 60℃ because this temperature is within the suitable range for the chemical reaction between the compound and wool fibers. At this temperature, the molecules possess appropriate activity, enabling the hydroxyl and carboxyl groups in the reagent to undergo chemical bonding reactions with active sites (such as amino groups) on the surface of the wool fibers, for example, forming amide bonds and ester bonds. The reaction time is set at 2.5 hours to ensure sufficient time for the reaction to proceed fully, allowing more reagent molecules to bind to sites on the fiber surface.

[0043] Physical modification primarily alters fiber properties by changing its internal physical structure. Methods include irradiation and heat treatment. Irradiation utilizes high-energy rays (such as ultraviolet light) to interact with the macromolecular chains within the fiber, breaking some chemical bonds and causing changes such as chain breakage and rearrangement. This alters structural parameters like crystallinity and orientation, improving the fiber's bulk and elasticity. Heat treatment, on the other hand, provides sufficient energy to the macromolecular segments within the fiber, intensifying chain movement and altering the distribution of previously ordered crystalline and amorphous regions. This optimizes the fiber's internal structure and also contributes to improving its relevant properties.

[0044] During mechanical modification, external forces are applied to the fibers using equipment such as carding machines. By adjusting key parameters such as the carding speed and force, the fibers are subjected to frictional and tensile forces of different directions and magnitudes as they pass through components such as the rollers and carding cloth of the carding machine. These external forces cause the fiber morphology to become straighter from its originally relatively disordered state, and the arrangement between the fibers becomes more compact and orderly, thereby enhancing the interaction between fibers and improving the overall physical properties of the fibers.

[0045] Chemical modification increases the number of hydrophilic groups on the fiber surface by approximately 30%, raising the moisture absorption rate to around 15% and controlling the dyeing color difference to ΔE*≤1.5. Physical modification alters the internal structure of the fiber, improving its bulkiness, elasticity, and thermal stability. Mechanical modification makes the fiber arrangement more compact and orderly, increasing the yarn breaking strength by approximately 15%, thus comprehensively improving the overall performance of wool fibers. This solves the problems of poor moisture absorption, insufficient bulkiness, and frequent yarn breakage during textile processing in wool fibers.

[0046] S3. Perform anti-yellowing treatment on the modified wool fibers to prevent yellowing during subsequent processing and use.

[0047] Specifically, S3 includes the following: The anti-yellowing solution is prepared by adding 0.4-0.5 kg of lemon juice to 10 kg of deionized water, heating and boiling to 92-95℃, and then adding 0.35-0.45 kg of skim milk. The fiber is soaked for about 4 hours. After this operation, a protective film with a thickness of about 50-80 nm is formed on the fiber surface. After 100 hours of accelerated aging test, the yellowing index does not increase by more than 5.

[0048] Specifically, lemon juice is rich in various organic acids, such as citric acid, and antioxidants like vitamin C. During the heating and boiling process, these organic acids can alter the chemical environment of the fiber surface to a certain extent, making it relatively acidic. This acidic environment helps inhibit some oxidation reactions that may cause fiber yellowing, because the activity of many substances that can cause fiber yellowing (such as some metal ions) is inhibited under acidic conditions, making their oxidation process difficult. At the same time, vitamin C, with its strong antioxidant properties, can preferentially react with free radicals and other reactive substances that may cause fiber oxidation and yellowing, thereby blocking the oxidation chain reaction process of fiber yellowing and protecting the fiber.

[0049] The protein component in skim milk is key. When skim milk is added to a boiling solution and comes into contact with fiber, the protein molecules undergo denaturation and aggregation under high temperature. Some protein molecules can adsorb onto the fiber surface, forming a physical barrier layer. This protein barrier layer can prevent substances that easily cause fiber yellowing (such as oxidizing gases in the air and certain impurities in dust) from directly contacting the fiber, reducing the likelihood of yellowing. Furthermore, proteins themselves have a buffering effect, creating a relatively stable microenvironment on the fiber surface, further reducing the risk of yellowing due to adverse external factors.

[0050] Deionized water, as a solvent, provides a uniform medium environment for the thorough mixing of lemon juice and skim milk and their subsequent interaction with the fiber, ensuring that the components can be evenly dispersed and function effectively. On the other hand, it dilutes the acidity of the lemon juice, preventing damage to the fiber due to excessive acidity, and maintaining the overall pH of the solution within a suitable range that can both prevent yellowing and avoid damaging the fiber.

[0051] The mixed solution was heated to a boiling point of 92-95℃, a key temperature range determined through repeated experiments. At this temperature, the active ingredients in lemon juice dissolve and are fully released, enhancing their antioxidant properties and regulating the chemical environment of the fiber surface. Simultaneously, the appropriately high temperature causes moderate denaturation of the proteins in skim milk, making them easier to adsorb and adhere to the fiber surface, forming a uniform and stable protective film. Furthermore, the higher temperature helps the solution better penetrate the pores and gaps within the fibers, allowing the fibers to fully contact the active ingredients in the anti-yellowing solution, thus improving the protective effect.

[0052] The fiber soaking time is set to approximately 4 hours to ensure that the fibers have sufficient time to fully absorb the effective components in the solution, and to allow substances such as proteins to effectively adsorb and aggregate on the fiber surface, forming a complete and dense protective film. During the soaking process, the components in the solution gradually adhere to the fiber surface and penetrate to a certain depth inside the fiber through diffusion, continuously exerting their anti-yellowing mechanism and providing long-lasting anti-yellowing protection for the fibers from multiple levels.

[0053] By preparing an anti-yellowing solution with a specific ratio, and after heating and soaking, a protective film of 50-80nm thickness can be formed on the fiber surface. In a 100-hour accelerated aging test, the yellowing index increases by no more than 5, effectively delaying fiber yellowing, maintaining good fiber color, and improving the stability of product appearance quality. This solves the problem of wool fibers easily yellowing due to natural aging and environmental factors, as well as yellowing during subsequent processing involving contact with chemical reagents and high temperatures.

[0054] S4. Antistatic treatment is applied to wool fibers after anti-yellowing treatment.

[0055] S4 specifically includes: the pretreatment solution is prepared based on the weight of wool fibers, with a reducing agent dosage of 10%, lipoic acid dosage of 2%, and the pH value strictly adjusted to 8.5; after the fibers are immersed in this pretreatment solution and heated to 60°C and kept at this temperature for 2 hours, the fiber surface resistivity decreases from the original 10... 13 Ω drops to 10 8 -10 9 Ω, the electrostatic voltage generated by friction can be controlled within 500V, and the electrostatic half-life is shortened to about 3 seconds.

[0056] Specifically, the reducing agent plays a crucial role in the pretreatment solution. Based on a specified weight of wool fibers, a 10% reducing agent can chemically react with some oxidizing functional groups on the wool fiber surface. The wool fiber surface originally contains some reducible chemical bonds and groups. The reducing agent, by providing electrons, promotes the reduction reaction of these groups, altering the chemical structure of the fiber surface. For example, it may reduce some high-valence sulfur- or oxygen-containing groups to low-valence states, changing the chemical activity of the fiber surface and creating conditions for the subsequent introduction of antistatic functional groups. It also helps improve the charge distribution on the fiber surface, reducing the possibility of charge accumulation.

[0057] The dosage of lipoic acid is 2%, and its molecular structure contains active sites such as carboxyl groups and sulfur atoms. In the pretreatment solution environment, lipoic acid can bind to the active sites exposed on the fiber surface after treatment with a reducing agent due to its own chemical activity. On the one hand, the carboxyl groups of lipoic acid can be attached to the fiber through chemical bonding (such as esterification, amidation, etc., depending on the specific active groups on the fiber surface); on the other hand, the groups containing sulfur atoms can also participate in the electron conduction process on the fiber surface, playing a certain role in charge transfer and dispersion, making it less likely for charges to accumulate on the fiber surface, thereby reducing the risk of static electricity.

[0058] The pH of the pretreatment solution was strictly adjusted to 8.5, an alkaline environment crucial for the entire pretreatment process. At this pH, the chemical activity of the reducing agent and lipoic acid reached a suitable level, allowing their chemical reactions with the fiber surface to proceed more smoothly. For example, for reactions involving active groups such as hydroxyl and amino groups, an alkaline environment helps promote proton transfer, accelerates the reaction rate, and ensures that the chemical modification of the fiber surface is fully and effectively completed, thereby optimizing the antistatic properties of the fiber.

[0059] When fibers are immersed in the pretreatment solution, the solution can fully contact and encapsulate the fibers. The reducing agents, thioctic acid, and other effective components in the solution gradually approach the fiber surface through diffusion. During this process, an interface for mass exchange and chemical reaction is formed between the fiber surface and the pretreatment solution. The components in the solution begin to interact with the functional groups on the fiber surface, laying the foundation for subsequent reactions.

[0060] Heating the impregnated fibers to 60°C and holding the reaction at that temperature for 2 hours is a key condition set based on the principles of chemical reaction kinetics. At 60°C, the thermal motion of molecules intensifies, significantly increasing the collision frequency between the molecules of the pretreatment solution and the groups on the fiber surface. This effectively overcomes the energy barrier of the chemical reaction and accelerates the reaction rate. Simultaneously, the 2-hour holding time ensures the reaction proceeds fully, allowing sufficient reducing agent and lipoic acid molecules to complete chemical bonding and other reaction processes with the fiber surface. This comprehensively and stably alters the chemical properties of the fiber surface, endowing the fiber with excellent antistatic properties.

[0061] By preparing a pretreatment solution containing a reducing agent and lipoic acid with a pH adjusted to 8.5 according to specific dosages, and then impregnating the fibers with the solution, the temperature was raised to 60°C and held for 2 hours, resulting in a reduction of the fiber surface resistivity to 10. 8 -10 9 With an electrostatic voltage controlled below 500V and a half-life reduced to approximately 3 seconds, the antistatic performance is significantly improved. This solves the problem of wool fibers becoming entangled and sticky due to static electricity during textile processing, which affects equipment and quality.

[0062] S5. Optimize the dyeing process for fibers that have undergone antistatic treatment.

[0063] Specifically, S5 includes: controlling the initial dyeing temperature at 42-48℃ for about 40 minutes, then increasing the temperature to 85℃ at a rate of 1℃ / minute, with a total dyeing time of about 2 hours, while stabilizing the pH value of the dyeing bath at about 5; through this segmented temperature dyeing process, the dye uptake rate reaches over 90%.

[0064] Specifically, in the low-temperature stage: during the initial dyeing process, the temperature is controlled within the relatively low range of 42-48℃. This is because at this temperature, the thermal motion of dye molecules is relatively mild, and their diffusion rate is moderate. Wool fibers have a complex scaly structure, and the macromolecular chain segments inside the fiber move relatively slowly at low temperatures. This environment allows dye molecules to approach the fiber surface relatively uniformly and slowly, giving them sufficient time to find active sites on the fiber surface, such as amino and carboxyl groups. Then, through relatively weak interactions such as van der Waals forces and hydrogen bonds, initial adsorption occurs, forming a relatively loose and uniformly distributed adsorption state. This stage avoids the situation where dye molecules accumulate too quickly on the fiber surface due to excessively high temperatures, resulting in excessive local adsorption and uneven dyeing.

[0065] Heating Phase: As the temperature is gradually increased at a rate of 1℃ / minute, the thermal motion of the macromolecular chains within the fiber becomes increasingly intense. The originally tightly packed structure begins to loosen, creating more channels within the fiber for dye molecules to diffuse into. Simultaneously, the thermal motion of the dye molecules themselves accelerates with increasing temperature, their kinetic energy continuously increasing. This allows them to overcome internal fiber resistance and gradually diffuse and penetrate into the fiber through the channels already formed on the fiber surface and the newly emerging internal channels. This slow and orderly heating process ensures that dye molecules are evenly distributed throughout the fiber, achieving thorough dyeing from the surface to the interior, guaranteeing uniform dyeing.

[0066] Stable high-temperature stage: When the temperature reaches 85℃ and is maintained for a period of time, the chemical reactivity between dye molecules and active sites on and inside the fiber reaches a high level. At this temperature, some dyeing reactions that can form strong chemical bonds such as covalent bonds can proceed fully. For example, sulfonic acid groups in acid dyes will form ionic bonds with amino groups on wool fibers. At the same time, some reactive dyes will undergo covalent bonding reactions with active groups on the fiber, making the dye molecules more firmly bound to the fiber and improving the fastness and stability of dyeing.

[0067] Maintaining a stable pH of around 5 in the dyeing bath is crucial because at this pH, the surface charge distribution and ionization state of the active groups on wool fibers are optimal for dye adsorption and binding. In a slightly acidic environment, the amino groups on wool fibers protonate, acquiring a positive charge. Most commonly used acidic dyes dissociate into negatively charged ions in solution. Through electrostatic attraction, these dye ions are more efficiently attracted to the fiber surface, leading to subsequent binding reactions. Simultaneously, this pH range prevents excessive damage to the fibers from overly strong acidity, ensuring that the fiber's physicochemical properties are not significantly affected, maintaining good dyeability and strength, and providing a suitable chemical environment for dye uptake.

[0068] By controlling the initial dyeing temperature at 42-48℃ for approximately 40 minutes, then gradually increasing it to 85℃ at a rate of 1℃ / minute and maintaining this temperature for about 2 hours, while simultaneously stabilizing the pH value of the dyeing bath at around 5, a segmented temperature dyeing process is achieved, resulting in a dye uptake rate of over 90%. This results in full-bodied, uniform fiber dyeing, enhancing the product's aesthetics and competitiveness. It also solves the problems of uneven dyeing, color differences, and uneven color distribution inherent in traditional dyeing processes.

[0069] S6. Perform finishing treatment on the dyed fibers.

[0070] S6 specifically includes: softening finishing using a 5% concentration of silicone softener solution, soaking the fibers for 30 minutes at 25°C, with the pick-up rate controlled at around 90%; after this treatment, the bending stiffness of the fabric is reduced by about 40% compared to before treatment, the surface friction coefficient is reduced to 0.2-0.3, and according to the five-level hand feel rating system, the hand feel score can be improved to more than 4 points.

[0071] Specifically, silicone fabric softeners contain silicon-oxygen segments in their molecular structure, which possess unique physicochemical properties. In a 5% solution, when fibers are immersed in it, the silicone fabric softener molecules interact with water molecules through their hydrophilic groups (such as hydroxyl groups), dispersing uniformly in the solution. Simultaneously, these molecules gradually approach the fiber surface through diffusion. Due to the very low surface energy of the silicon-oxygen segments, they can align themselves on the fiber surface. The active groups at one end (such as amino or epoxy groups, depending on the specific type of silicone fabric softener) chemically bond or physically adsorb onto the active sites on the fiber surface (such as hydroxyl or carboxyl groups on the fiber), thus firmly adhering to the fiber surface.

[0072] The fibers were soaked at 25°C for 30 minutes; this temperature and time were optimized. The 25°C temperature ensured that the silicone softener molecules had suitable activity and diffusion rate, while preventing excessive evaporation of the solution or adverse effects on the fibers due to excessive heat. The 30-minute soaking time allowed the fibers to fully contact the softener solution, enabling a sufficient number of softener molecules to adsorb onto the fiber surface and penetrate to a certain depth.

[0073] The roll-off rate is controlled at around 90%. During the roll-off process, a certain pressure is applied to the fiber through the rollers, causing excess solution to be squeezed out as the fiber passes through the rollers, while ensuring that an appropriate amount of softener solution remains on the fiber. This avoids problems such as increased subsequent drying costs and uneven drying caused by excessive solution. On the other hand, it ensures that enough softener remains on the fiber, allowing it to better form a uniform and continuous softener film layer on the fiber surface during the subsequent drying process, achieving the best softening finishing effect.

[0074] By employing a softening finishing process that involves soaking fibers in a 5% silicone softener solution at 25°C for 30 minutes with a roll-off rate controlled at approximately 90%, the fabric's bending stiffness is reduced by about 40%, the surface friction coefficient is lowered to 0.2-0.3, and the hand feel score is improved to over 4 points. This significantly improves the hand feel, enhancing product comfort and market competitiveness. It also solves the problem of rough hand feel affecting fabric quality and poor hand feel after dyeing.

[0075] S7. Implement quality monitoring throughout the entire production process of worsted wool fabrics and conduct comprehensive testing on the finished products.

[0076] Specifically, S7 includes the following physical performance tests for finished products: tensile strength must reach 350-450N, tear strength must reach 20-25N, air permeability must reach 150-250mm / s, bursting strength must reach 300-400N, and elongation at break must be controlled between 30% and 40%.

[0077] S7 also includes: in the chemical performance testing of finished products, the pH value must be between 5 and 7, the formaldehyde content must be strictly limited to below 75 mg / kg, the content of decomposed aromatic amine dyes must not exceed 20 mg / kg, and all color fastness indicators must reach level 4 or above.

[0078] Specifically, implementing quality monitoring throughout the entire worsted wool fabric production process is based on the complexity of the production flow and the interconnectedness of each stage. From the initial pretreatment of wool fibers to subsequent modifications, anti-yellowing, antistatic treatments, dyeing, and finishing processes, fluctuations in process parameters and the degree of operational standardization at each stage will affect the final product quality. For example, in the carding stage, deviations in parameters such as the speed and force of the carding machine will alter the fiber morphology and arrangement, thus affecting the quality of subsequent spinning and weaving. By installing corresponding online detection equipment at key process nodes, such as yarn evenness detectors during spinning and fabric density monitors during weaving, various quality-related data can be collected in real time during production. This allows for the timely detection of quality fluctuations, enabling rapid adjustments to the corresponding process parameters and ensuring stable production that progresses towards meeting quality requirements.

[0079] The testing of indicators such as tensile strength, tear strength, and bursting strength is conducted using specialized mechanical property testing equipment, following the corresponding national standard testing methods. Taking tensile strength testing as an example, a woolen worsted fabric sample of a certain specification is clamped between the upper and lower clamps of a tensile testing machine. The sample is then stretched slowly and uniformly. The equipment records the applied tensile force and the elongation of the sample in real time until the sample breaks. The maximum tensile force measured at this point is the tensile strength. These strength indicators reflect the fabric's ability to resist damage when subjected to external forces. Their values ​​are closely related to factors such as the strength of the fibers themselves, the cohesion between fibers, and the fabric's structure. Specific numerical ranges (e.g., tensile strength needs to reach 350-450N, tear strength needs to reach 20-25N, and bursting strength needs to reach 300-400N) are determined through extensive actual production testing and with reference to industry standards and actual product usage requirements, ensuring that the product can withstand normal external forces such as pulling and friction during wear and use without easily breaking.

[0080] Air permeability testing is performed using an air permeability tester. A sample of worsted wool fabric is placed in the test chamber of the instrument, and a certain air pressure difference is applied to one side, allowing air to pass through the fabric. The instrument measures air permeability by detecting the airflow rate through a unit area of ​​fabric per unit time. An air permeability of 150-250 mm / s is required. The air permeability of a fabric is related to the type of fiber, the twist of the yarn, and the fabric's structure (such as warp and weft density, fabric thickness, etc.). Appropriate air permeability ensures wearing comfort, allowing the skin to breathe normally and avoiding stuffiness and other discomfort.

[0081] Similarly, using mechanical property testing equipment, in addition to recording the maximum tensile force during tensile testing of the samples, the elongation change of the sample from the start of stretching to breakage is precisely measured. By calculating the ratio of the elongation to the original sample length, the elongation at break is obtained and controlled between 30% and 40%. The elongation at break reflects the fabric's ability to deform under stress. A suitable elongation at break ensures that the fabric has a certain degree of elastic deformation after being subjected to stress, but will not be unable to return to its original shape or break directly due to excessive elongation, thus affecting the product's durability and appearance.

[0082] pH value is measured on finished wool and worsted fabrics using a pH meter. The pH value of a fabric is affected by various factors, including the fiber raw material itself, chemical reagents used in processing (such as acids and alkalis), and finishing processes. The sample is cut into small pieces, soaked in a certain amount of distilled water, thoroughly stirred, and allowed to stand. The pH value of the solution is then measured using a pH meter. It is specified that the pH should be between 5 and 7 because human skin is slightly acidic (pH value approximately between 4.5 and 6.5). Fabrics within this pH range will not irritate the skin due to excessive differences in acidity or alkalinity, thus ensuring safety and comfort when worn.

[0083] Formaldehyde content testing utilizes professional formaldehyde detection instruments and is conducted according to relevant national standard methods (such as the acetylacetone spectrophotometric method). During the production process, some finishing agents and additives may release formaldehyde. Formaldehyde is a volatile organic compound that is harmful to the human body, and long-term exposure may endanger human health. By using precise detection methods and strictly limiting the formaldehyde content to below 75 mg / kg, its potential harm to human health can be effectively reduced, ensuring that the product meets environmental protection and health requirements.

[0084] For the detection of the content of decomposition aromatic amine dyes, high-precision analytical methods such as high-performance liquid chromatography are employed. Under certain conditions, decomposition aromatic amine dyes may decompose to produce carcinogenic aromatic amine compounds. Once these compounds come into contact with human skin, they may be absorbed into the body through the skin, posing a serious threat to health. Therefore, the content is stipulated to not exceed 20 mg / kg, eliminating the presence of these harmful substances in products at the source and ensuring product safety.

[0085] Colorfastness testing encompasses various types, such as colorfastness to rubbing, colorfastness to washing, and colorfastness to sunlight, conducted by simulating corresponding real-world usage scenarios. For example, the colorfastness to rubbing test involves rubbing the sample against a specified rubbing cloth under a certain pressure, then comparing the color changes of the sample and the rubbing cloth before and after rubbing, and assigning a grade according to standard rating methods. All colorfastness indicators must reach grade 4 or higher. Good colorfastness ensures that fabrics do not easily fade or discolor during daily wear, washing, and sun exposure, maintaining the product's aesthetic appeal and quality stability.

[0086] By implementing quality control throughout the entire production process of worsted wool fabrics and conducting comprehensive testing of finished products, specific ranges are set for physical properties such as tensile strength, tear strength, air permeability, and elongation at break. Chemical properties, including acidity / alkalinity, formaldehyde content, and color fastness requirements, stable product quality is ensured, meeting relevant standards and enhancing market competitiveness and brand image. This solves the problem of quality fluctuations and inconsistent product quality caused by multiple factors during production.

[0087] The efficient carding method for worsted wool fabrics involves multiple steps. S1, the degreasing process, utilizes organic solvents or chemical reagents, leveraging the principle of "like dissolves like," to dissolve or transform grease and impurities on the surface of wool fibers, improving their surface properties and creating favorable conditions for subsequent processing. For example, organic solvent molecules can penetrate the grease layer, disrupting the bond between the grease and the fiber and carrying it away.

[0088] S2. Modification treatments address these issues through chemical, physical, and mechanical means. Chemical modification involves using specific reagents to react with the fiber, such as graft copolymerization, introducing functional groups like hydroxyl and carboxyl groups onto the fiber surface to alter its chemical properties. Physical modification utilizes methods like irradiation and heat treatment to change the internal macromolecular chain structure of the fiber. For example, irradiation causes chain breakage and cross-linking, while heat treatment promotes chain segment rearrangement and controls parameters such as crystallinity and orientation. Mechanical modification uses textile machinery to apply external force, adjusting the fiber morphology and arrangement to enhance cohesion.

[0089] S3, anti-yellowing treatment, relies on a solution containing antioxidants and substances that can form a protective film, which is applied to the fiber surface through soaking, coating, or other methods. The antioxidants capture free radicals, inhibiting oxidative yellowing, while the protective film blocks external factors, combining internal and external treatments to prevent the fibers from yellowing.

[0090] S4. Antistatic treatment involves two methods: first, using antistatic agents adsorbed on the fiber surface to conduct away charges through their electrical or ionic conductivity; and second, introducing conductive functional groups through chemical modification to reduce the surface resistance of the fiber and decrease the generation and accumulation of static electricity.

[0091] S5. The dyeing process is optimized by adopting segmented heating. Based on the characteristics of dyes and fibers, dye molecules are allowed to adsorb, diffuse and combine in an orderly manner at different temperature stages. The pH of the dyeing bath is precisely controlled to create a suitable chemical environment. At the same time, dyes and auxiliaries are selected in a reasonable manner to ensure uniform and efficient dyeing.

[0092] S6. Finishing treatment: Softeners, anti-shrinkage agents and other additives are used in processes such as padding and baking to allow them to physically adsorb or chemically react with the fibers, forming a functional film layer on the fiber surface. For example, softeners reduce the coefficient of friction and improve the feel, while anti-shrinkage agents inhibit fiber shrinkage.

[0093] S7. Quality monitoring and finished product inspection: Install testing equipment in each key production process to collect data in real time and adjust parameters promptly when abnormalities are detected; conduct comprehensive physical and chemical performance testing on finished products and determine whether they are qualified according to standards to ensure stable product quality.

[0094] The efficient combing methods used in worsted wool fabrics enhance fiber cleanliness and activity, facilitating subsequent processing. Multi-dimensional modification improves fiber performance, preventing yellowing and maintaining color, reducing static electricity, and optimizing dyeing processes for uniform, fast, and efficient dyeing. Finishing enhances wearability, while comprehensive quality monitoring and testing ensure stable product quality. This comprehensively improves product aesthetics, comfort, durability, and market competitiveness, meeting market and consumer demands. It solves the problem that the overall performance of wool fibers is insufficient to meet the high-quality requirements of worsted wool fabrics.

[0095] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method of high efficiency carding of wool worsted suiting characterized in that, It comprises the following steps: S1, the wool fiber is sequentially subjected to degreasing treatment, impurities are removed, and the fiber surface performance is improved to prepare for subsequent processing; S2, the modified treatment is carried out on the pretreated wool fiber, and the fiber characteristics are changed from the aspects of chemistry, physics and mechanics; S3, the anti-yellowing treatment is carried out on the modified wool fiber, to prevent the fiber from yellowing during subsequent processing and use; S4, the anti-static treatment is carried out on the wool fiber after the anti-yellowing treatment; S5, the dyeing process optimization is carried out on the fiber after the anti-static treatment; S6, the finishing treatment is carried out on the dyed fiber; S7, quality monitoring is set in the whole process of wool worsted fabric production, and the finished product is comprehensively detected.

2. The high efficiency carding process for wool worsted suiting according to claim 1, characterized in that, In S1, the degreasing treatment uses acetone solution, the treatment temperature is controlled at 28-32℃, and the treatment time is about 2 hours; under this temperature and time, the concentration of acetone solution is maintained at 80%, which can fully remove the oil on the surface of wool fiber, and the oil content of the treated fiber is reduced to below 0.5%, creating good conditions for subsequent treatment, so that the subsequent chemical reagents can contact the fiber more fully.

3. The high efficiency carding process for woolen spun suiting fabric as claimed in claim 1 wherein, In S2, the concentration of the compound reagent containing hydroxyl and carboxyl groups used in chemical modification is 8%, the reaction temperature is accurately controlled at 60℃, and the reaction time is set to 2.5 hours; after this treatment, the number of hydrophilic groups on the surface of the fiber increases by about 30%, and the moisture absorption rate increases to about 15% compared with that before treatment, and the color difference during dyeing can be controlled to ΔE*≤1.

5.

4. The high efficiency carding process for woolen spun suiting fabric as claimed in claim 1 wherein, In S3, the preparation of the anti-yellowing solution is to add 0.4-0.5 kg of lemon juice to 10 kg of deionized water, heat to boiling to 92-95℃, and then add 0.35-0.45 kg of skimmed milk, and the fiber soaking time is about 4 hours; after such operation, a protective film with a thickness of about 50-80 nm is formed on the surface of the fiber, and after 100 hours of accelerated aging test, the yellowness index increases by not more than 5.

5. The high efficiency carding process for woolen spun suiting fabric as claimed in claim 1 wherein, The S4 specifically includes: when the pretreatment liquid is prepared, the amount of reducing agent is 10% based on the weight of wool fiber, the amount of lipoic acid is 2%, and the pH value is strictly adjusted to 8.5; after the fiber is immersed in the pretreatment liquid and heated to 60℃ and kept for 2 hours, the surface resistance of the fiber is reduced from the original 10 13 Ω to 10 8 -10 9 Ω, the electrostatic voltage generated by friction can be controlled within 500V, and the electrostatic half-life is shortened to about 3 seconds.

6. The high efficiency carding process for woolen spun suiting fabric as claimed in claim 1 wherein, In S5, the initial dyeing temperature is controlled at 42-48℃, and the holding time is about 40 minutes, then the temperature is raised to 85℃ at a rate of 1℃ / min, the total dyeing time is about 2 hours, and the pH value of the dyeing bath is stabilized at about 5; through this segmented warm dyeing process, the dyeing rate of the dye reaches more than 90%.

7. The high efficiency carding process for woolen spun suiting fabric as claimed in claim 1 wherein, In S6, the soft finishing uses a silicone softener solution with a concentration of 5%, the fiber is soaked at 25℃ for 30 minutes, and the pick-up rate is controlled at about 90%; after this treatment, the bending stiffness of the fabric is reduced by about 40% compared with that before treatment, the surface friction coefficient is reduced to 0.2-0.3, and the hand feel score can be improved to more than 4 points according to the five-level hand feel scoring system.

8. The high efficiency carding process for woolen spun suiting fabric as claimed in claim 1 wherein, In S7, in the physical performance test of finished product detection, the tensile strength needs to reach 350-450N, the tear strength needs to reach 20-25N, the air permeability needs to reach 150-250mm / s, the bursting strength needs to reach 300-400N, and the elongation at break needs to be controlled between 30%-40%.

9. The high efficiency carding process for woolen spun suiting fabric as claimed in claim 1 wherein, The S7 also includes: finished product detection of chemical performance test, pH value needs to be between 5-7, formaldehyde content is strictly limited to 75mg / kg below, the decomposition of aromatic amine dye content should not exceed 20mg / kg, each color fastness index reaches 4 or more.

Images