Fine and soft dyeing and finishing process of home textile wide woven fabric

Abstract

The invention provides a soft dyeing and finishing process of a home textile wide woven fabric. The soft dyeing and finishing process comprises the following steps of pretreatment, dyeing, water flow soft washing, enzyme soft washing treatment, soft finishing and shrinking. Wherein a compound enzyme preparation formed by compounding amylase, saccharifying enzyme and cellulase is used for carrying out stacking desizing, dyeing fixation is completed in a padding-cold batch mode of double-active-group dye and compound dyeing substitution alkali, villus is formed under the conditions of mechanical grid equipment impact, loose flow field impact and a compound fiber expanding agent, and the villus is used for dyeing. Neutral cellulase and a bath smoothing agent are adopted to remove surface hairiness and primary cell walls, and a polyether modified silicone oil and nano microcapsule softener compounding process is used for padding and finishing. The super-soft suede fabric solves the problems that an existing super-soft suede fabric is high in hair slip rate, poor in air permeability, hardened after being washed, low in high-count suede yarn breaking strength and broken.

Description

Technical Field

[0001] This invention relates to the field of textile dyeing and finishing technology, specifically to a soft dyeing and finishing process for wide-width woven fabrics used in home textiles. Background Technology

[0002] Currently, the dyeing and printing industry generally achieves a velvety feel in fabrics through napping and brushing processes. However, obtaining a short and dense velvety feel requires precise control of the brushing process on the equipment. Generally, brushed fabrics are better suited to napping or brushing with coarser yarn counts, resulting in a longer and thicker velvet texture. While achieving the velvety feel, it's crucial to ensure that some strengths remain within the standard acceptable range. For example, high-count fabrics (60S or 80S and above) are generally unsuitable for napping or brushing processes because they are prone to yarn breakage and fabric defects. The brushing process creates a velvety layer on the fabric surface through mechanical friction. This process damages the fiber structure, leading to reduced abrasion resistance and tensile strength, especially for fabrics containing natural fibers such as pure cotton. Long-term use or frequent washing can easily result in pilling and damage. In addition, the lint produced by brushing is easy to fall off during initial use or washing, which may affect the appearance of the product (such as lint sticking to clothes and sheets), and the accumulation of lint may clog the washing machine filter, increasing cleaning and maintenance costs. During the printing and dyeing process, the rough surface of the fabric after brushing may lead to uneven dye penetration, resulting in decreased color fastness (especially on dark fabrics) or blurred printed patterns that affect the fineness of the design. Furthermore, the lint layer may absorb excess dye, increasing the difficulty of washing and reducing wash fastness. On the other hand, the fiber opening process is mainly for lyocell and its blended fabrics. In particular, chemical or mechanical fiber opening requires separating composite fiber bundles into monofilaments. If the process is not handled properly (such as poor control of temperature or auxiliary agent concentration), it may lead to fiber breakage or uneven fineness, weakening the overall strength of the fabric. This problem is more likely to occur with microfiber. Although the fabric after fiber opening (such as high-density microfiber fabric) is soft to the touch and highly absorbent, the reduced fiber gaps may lead to decreased breathability. It may cause a stuffy feeling (itchy feeling) when used in summer. Therefore, the fleece-like fabric is more suitable for spring, autumn, and winter. In addition, trace amounts of solvent residue from chemical fiber opening may have a certain impact on sensitive skin, affecting skin-friendliness. In the printing and dyeing process, because the surface of the fabric after fiber opening is delicate, the uniformity of printing and dyeing and finishing (such as waterproofing and stain-resistant treatment) is more important. Otherwise, problems such as poor coating adhesion and color unevenness may occur. In addition, microfiber fabrics are prone to sticking after fiber opening, requiring additional antistatic or anti-sticking treatment steps, which increases production costs.

[0003] Therefore, obtaining a high-count, ultra-short, dense, fine-pile fabric that is also lustrous, has a delicate and soft feel, and excellent skin-friendly and breathable properties remains a current industry bottleneck. Furthermore, addressing issues such as high shedding rate, poor breathability, hardening after washing, yarn breakage and tearing in high-count brushed fabrics also urgently requires research. Summary of the Invention

[0004] The purpose of this invention is to provide a soft dyeing and finishing process for wide-width woven fabrics for home textiles, in order to solve the problems of high shedding rate, poor breathability, hardening after washing, high-count brushed yarn breakage and damage, and holes in current ultra-soft brushed fabrics, and to obtain a high-count yarn, ultra-short and dense fine brushed fabric that is also lustrous, has a delicate and soft feel, and has better skin-friendly and breathable properties.

[0005] The present invention also aims to provide a fine dyeing and finishing process suitable for wide-width woven fabrics of high-count yarn home textiles, which can obtain micron-level, fine and dense splitting fluff without damaging the fiber strength, thereby improving skin-friendliness, softness and breathability, while solving the problems of high shedding rate, poor color fastness and inability to abrade high-count yarns.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A delicate dyeing and finishing process for wide-width woven fabrics used in home textiles, the process comprising the following steps: S1 Pretreatment: After singeing the fabric, the fabric is desized by stacking it with a compound enzyme preparation composed of amylase, saccharifying enzyme and cellulase. S2 dyeing: The cold pad-batch dyeing process is adopted, which completes the dyeing and fixing by pad-cold-batch method of dual reactive dyes and compound dyeing substitute alkali, and constructs an alkaline buffer environment. After dyeing, the fabric is washed and the pH value is neutralized. S3 Water Flow Soft Wash: The fabric obtained in step S2 is placed under acidic conditions and treated with a loose water flow airflow treatment device. Under the conditions of impact from mechanical grid equipment or loose flow field impact from dyeing vat equipment, and in conjunction with a fiber swelling agent, it is treated under acidic high temperature conditions to form soft fluff. S4 Enzyme Soft Wash Treatment: Neutral cellulase and bath smoothing agent are used to remove surface hairs and primary cell walls, forming a soft, hairy feel. The enzyme reaction is controlled by heating and inactivation with soda ash. S5 softening finish: Polyether modified silicone oil and nano-microcapsule softener are compounded, impregnated, dried and baked to form a surface lubricating film and an internal slow-release structure; S6 shrinkage: Controllable shrinkage force is applied in a humid and hot steam environment using rubber or felt blankets to eliminate internal stress.

[0007] Other applicable areas will become apparent from the description provided in this disclosure.

[0008] The descriptions and specific examples in the invention summary are intended to be illustrative only and are not intended to limit the scope of this disclosure.

[0009] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects: 1. This invention solves the problems of high shedding rate, poor breathability, hardening after washing, high-count brushed yarn breakage and damage in current ultra-soft brushed fabrics, and obtains a high-count yarn, ultra-short and dense fine soft brushed fabric, which is also lustrous, delicate and soft to the touch, and has good skin-friendly and breathable properties. 2. The fabric provided by this invention has a hand feel of super soft (level 4) or above, a static drape coefficient of <30%, a super soft hand feel, and a shedding rate of <0.6%, which is of superior quality. 3. This invention uses a loose-flow water and air treatment device with "acidic expansion + mechanical gas-liquid impact" to make high-count wide fabrics form micron-level, non-abrasion-breaking dense splitting fluff, thereby obtaining excellent fluffy feel, skin-friendly and fastness performance. This systematic fiber softening process subverts the technical bottleneck that traditional "brushing / fiber opening" is powerless against high-count yarns. 4. This invention provides a fine and soft dyeing and finishing process suitable for wide-width woven fabrics of high-count yarn home textiles. It can obtain micron-level, fine and dense splitting and brushing fluff without damaging the fiber strength, thereby improving skin-friendliness, softness and breathability. At the same time, it solves problems such as high shedding rate of brushing, poor color fastness and the inability of high-count yarns to be brushed. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other solutions can be obtained based on these drawings without creative effort.

[0011] Figure 1 The microstructure of the brushed fabric 40S / 32S in the prior art and the soft fabric 80S / 60S provided in an embodiment of the present invention; Figure 2 for Figure 1 The surface morphology of the brushed fabric 40S / 32S and the soft fabric 80S / 60S observed under a light box. Figure 3 for Figure 1 The cross-sectional morphology of the brushed fabric 40S / 32S and the soft fabric 80S / 60S provided by the present invention observed under a light box. Detailed Implementation

[0012] The technical solutions in the embodiments of the present invention will be clearly and completely described below. 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. It should be understood that the specific embodiments described herein are only for illustration and explanation of the present invention and are not intended to limit the present invention.

[0013] Any specific numerical values ​​disclosed herein (including the endpoints of numerical ranges) are not limited to their exact values, but should be understood to also include values ​​close to the exact value, such as all possible values ​​within ±5% of the exact value. Furthermore, with respect to the disclosed numerical ranges, one or more new numerical ranges can be obtained by arbitrarily combining the endpoint values ​​of the range, the endpoint values ​​with specific point values ​​within the range, and the specific point values ​​themselves; these new numerical ranges should also be considered as specifically disclosed herein.

[0014] The terminology used in this disclosure is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” as used in this disclosure are intended to include the plural forms as well. The terms “comprising,” “including,” “containing,” and “having” are inclusive and thus describe the presence of said features, elements, compositions, steps, integers, operations, and / or components, but do not exclude the presence or inclusion of one or more other features, integers, steps, operations, elements, components, and / or sets thereof. Although the open-ended term “comprising” should be understood as a non-limiting term used to describe and claim the various embodiments described in this disclosure, in some aspects it may instead be understood as a more restrictive and limiting term, such as “consisting of” or “substantially consisting of.” Thus, for any given embodiment describing a composition, material, component, element, feature, integer, operation, and / or process step, this disclosure also particularly includes embodiments consisting of or substantially consisting of such compositions, materials, components, elements, features, integers, operations, and / or process steps. In the case of “consisting of…”, the alternative embodiments exclude any additional compositions, materials, components, elements, features, integers, operations and / or process steps. In the case of “essentially composed of…”, any additional compositions, materials, components, elements, features, integers, operations and / or process steps that substantially affect the essential and novel characteristics are excluded from such embodiments. However, any compositions, materials, components, elements, features, integers, operations and / or process steps that do not substantially affect the essential and novel characteristics may be included in the embodiments.

[0015] Any method steps, processes, and operations described in this disclosure should not be construed as necessarily requiring them to be performed in a particular order as discussed or shown, unless explicitly specified. It should also be understood that additional or alternative steps may be used unless otherwise stated.

[0016] In this application, except where expressly stated, any matters or issues not mentioned are directly applicable to those known in the art without any modification. Furthermore, any implementation described in this disclosure may be freely combined with one or more other implementations described in this disclosure, and the resulting technical solutions or concepts shall be considered part of the original disclosure or original record of this application, and should not be regarded as new content not disclosed or anticipated in this disclosure, unless those skilled in the art consider the combination to be clearly unreasonable.

[0017] Unless otherwise stated, the terms used herein have the same meaning as commonly understood by those skilled in the art, and if a term is defined herein and its definition differs from the common understanding in the art, the definition herein shall prevail.

[0018] Unless otherwise stated, when % is mentioned in this document, it refers to wt%.

[0019] It is worth noting that "bath smoothing agents" in the textile industry are chemical auxiliaries added to dyeing, scouring, or finishing solutions (i.e., "bath solutions"). Their main functions are: 1. To improve the smoothness of fibers, as smoothing agents can form a soft, lubricating film on the fiber surface, making the fabric smoother, softer, and fuller; 2. To reduce friction between fibers, thus preventing fiber damage during processing (such as pilling, fuzzing, and breakage), especially in high-temperature or high-mechanical-force processes (such as jet dyeing machines); 3. To enhance the abrasion resistance, wrinkle resistance, and antistatic properties of fabrics. Some smoothing agents also have certain antistatic or anti-yellowing effects; 4. To improve the smoothness of dyeing and finishing processes, reducing entanglement, friction, and wrinkling of fabrics in dyeing baths or finishing solutions. Furthermore, unlike finishing processes (such as padding and exhaustion) where auxiliaries are added directly, in-bath smoothing agents are added directly to the working solution during dyeing or other wet treatment processes. For example, smoothing agents are added to the dye bath during high-temperature, high-pressure dyeing; during enzyme treatment (such as biopolishing), smoothing agents are added to prevent fuzzing and abrasion; and in scouring-bleaching baths to improve anti-friction properties. Precautions for using in-bath smoothing agents include: considering their compatibility with dyes and other auxiliaries; controlling the amount added appropriately to prevent affecting subsequent processing (such as darkening of color or silicone spots); and selecting low-yellowing, environmentally friendly products that meet textile product standards and export standards.

[0020] It's worth noting that in the textile industry, "loose-form flow field" typically appears in the technical descriptions of dyeing and finishing equipment (especially dyeing machines). It refers to a process or equipment structure where the fabric is propelled and circulated by a liquid flow in a loose, relaxed state. This concept contrasts with "tight" or "in-cylinder roll-up" flow fields. A loose-form flow field refers to a fabric existing in a loose, relaxed, untensioned, and untangled state during dyeing or treatment, and its circulation within the equipment is driven by liquid or gas-liquid flow. It is mainly used in modern dyeing and finishing equipment such as jet dyeing machines, overflow dyeing machines, airflow dyeing machines, and loose-form roll-up dyeing machines, and is particularly suitable for processing lightweight, easily deformed, and wrinkled fabrics. The fabric moves in a naturally curled, loose, and relaxed state in the equipment, unaffected by tension or with minimal tension; the flow field driving force is driven by the high-speed dye liquor flow or gas-liquid mixture flow generated by the jet or overflow port, allowing the fabric to move freely; suitable for knitted fabrics, lightweight woven fabrics, and elastic fabrics; it has the advantages of good dyeing uniformity, minimal fabric deformation, less pilling and fuzzing, and reduced breakage and tangling.

[0021] Currently, existing wide-width woven fabrics for home textiles suffer from the following problems: 1. Yarns are easily broken, leading to a decrease in strength; 2. Pilling occurs, affecting the user experience; 3. Color fastness is poor, with excessive dye floating and severe color fading after washing; 4. The pile is coarse and unevenly distributed, affecting skin-friendliness and breathability; 5. High-count yarn fabrics, due to their fine yarn count and dense structure, are difficult to achieve a short, fine pile effect. Based on this, the present invention specifically provides the following technical solution to solve the above-mentioned technical problems.

[0022] First aspect This invention provides a soft dyeing and finishing process for wide-width woven fabrics used in home textiles, comprising the following steps: S1 Pretreatment: After singeing the greige fabric, desizing is performed using a compound enzyme preparation composed of amylase, saccharifying enzyme, and cellulase to remove sizing and reduce fiber damage; S2 Dyeing: A cold pad-batch dyeing process is adopted, using a pad-cold-batch method with dual reactive dyes and a compound dyeing alkali substitute to complete dyeing and fixation, and to create an alkaline buffer environment. After dyeing, the fabric is washed and the pH of the fabric is neutralized; S3 Soft Water Wash: The fabric obtained in step S2 is placed under acidic conditions and treated with a loose water flow air treatment device. Under the conditions of impact from mechanical grid equipment or loose flow field impact from dyeing vat equipment, and in conjunction with a fiber swelling agent, the fabric is treated under acidic high temperature conditions to soften the fibers. Radial expansion, skin rupture, and fibrillation create ultra-short and dense micron-sized soft fibers; S4 Enzyme Softening Treatment: Neutral cellulase and in-bath smoothing agent are used to further remove surface fuzz and primary cell walls, creating a soft, velvety feel. The enzyme reaction is controlled by heating and using soda ash to inactivate the enzymes, improving the hand feel, enhancing luster, and preventing strong damage; S5 Softening Finishing: Polyether-modified silicone oil and nano-microcapsule softener are combined, impregnated, dried, and baked to form a surface lubricating film and an internal slow-release structure, giving the fabric lasting softness and achieving a durable, hydrophilic, and ultra-soft feel; S6 Shrinkage: Controlled shrinkage force is applied in a humid and hot steam environment using a rubber blanket to eliminate internal stress, stabilize dimensions, and enhance the feel, achieving pre-shrinkage and further improving the hand feel.

[0023] The above technical solution solves the problem of high-count yarns being unable to be napped. Specifically, through acid expansion and physical loose impact, a non-abrasion-induced filament splitting process is achieved; significantly improving the fabric's skin-friendliness and breathability: micron-level, fine nap replaces the rough nap layer, enhancing the skin feel; furthermore, it improves color fastness and anti-pilling and anti-hair loss performance: the non-fracture nap structure has a high strength retention rate and less loose dye; not only that, but the production is also greener and more environmentally friendly: process energy consumption, chemical residues, and water consumption are all significantly reduced; in addition, the above process provided by this invention has the advantages of strong controllability and wide applicability, and is applicable to various high-count satin fabrics such as Lyocell, Lyocell cotton, and high-count satin yarns.

[0024] It is worth noting that, compared with existing technologies, this invention does not employ traditional mechanical abrasion or chemical fiber opening methods, but instead introduces a composite method of "acidic expansion + loose mechanical impact," achieving for the first time the formation of stable ultra-fine nap from high-count yarns. Furthermore, by utilizing water flow gentle washing combined with enzymatic hydrolysis, the hand feel and luster are optimized while maintaining strength. In addition, a softening finishing technology combining polyether-modified silicone oil and nanocapsules is used, which is an innovation that cannot be matched by existing single softeners.

[0025] The fiber softening process provided by this invention significantly improves pilling resistance, fuzz control, and colorfastness. Specifically: the fiber ends are bulged, torn, and split into fine fibers. Then, a water flow under certain pressure impacts the fiber bundles, causing them to disperse and forming micron-level split-fiber pile on the fabric surface. This results in an ultra-short and densely packed pile fabric. The fibers are split rather than ground or cut, resulting in a low radial friction coefficient, whereas brushing results in a high cross-sectional friction coefficient, leading to greater friction and easier shedding. This process also improves anti-pilling and rubbing resistance. Further gentle washing after dyeing effectively removes excess dye and improves colorfastness. Acidification and mechanical gentle washing further enhance the fiber... This fabric is soft, velvety, and has a unique velvety feel with a fluffy and supple texture. Under acidic conditions, the fibers are torn and separated through water flow and mechanical grid equipment, highlighting the inherent fluffiness of the cellulose fibers. This non-mechanical cutting process, without the use of abrasive fiber breaking technology, results in less broken fibers and superior pilling and shedding performance. The unique velvety feel and soft, supple texture further address the problem of poor luster in existing velvety fabrics. Specifically, it uses enzymes to decompose the fuzz and nascent cell walls on the fiber surface, further improving pilling and shedding while making the disordered fluff more uniform and dense, giving the fabric a good luster.

[0026] Furthermore, this invention addresses the industry's pain point that high-count yarns are unsuitable for brushing processes. Brushing typically requires coarse-count yarns such as 10S, 20S, 30S, and 40S. Because brushing achieves its effect by breaking fibers to form a nap, the coarser yarn count, along with limitations in pre-treatment and post-treatment, results in poor softness and drape. Additionally, brushing significantly reduces strength, and high-count yarns are prone to breakage, causing a substantial decrease in strength and failing to meet required specifications. In contrast, the fine-textured yarn provided by this invention does not break fibers but rather separates them into fine strands, resulting in less strength loss and a superior feel, excellent drape, and ultra-softness—unmatched by conventional brushed fabrics. Through specific post-treatment processes, this invention produces a soft and smooth fabric without any stiffness or graininess, while maintaining an excellent feel and style even after washing.

[0027] Furthermore, starting from the pretreatment process, the present invention performs a piling treatment under weak alkaline (relative to the caustic soda boiling process) at room temperature, which meets the essential conditions for printing and dyeing while significantly reducing energy consumption by 30% to 50%. The dyeing process adopts a cold piling dyeing method, which is gentle and can save energy and protect the environment without damaging the fabric. Since room temperature dyeing is achieved, energy consumption is significantly reduced by 50% to 60%.

[0028] In some embodiments of the present invention, in step S1, the singeing process is carried out using a German OTHOFF OS07-4 singeing machine, and the sample is stacked at room temperature for 8 to 10 hours.

[0029] In some embodiments of the present invention, in step S1, the mass ratio of amylase, saccharifying enzyme, and cellulose is 80:5:15.

[0030] In some embodiments of the present invention, the compound enzyme preparation is compound enzyme preparation T5050.

[0031] In some embodiments of the present invention, in step S1, the deslurry removal is carried out at room temperature.

[0032] In some embodiments of the present invention, in step S2, the cold pad-batch dyeing process employs a compound dyeing substitute alkali. The compound dyeing substitute alkali added to the dye liquor in S2 is a dyeing alkali agent that aids in dye uptake and fixation during cold dyeing. Using the compound dyeing substitute alkali enables the dye to be applied and fixed during the cold dyeing process.

[0033] In some embodiments of the present invention, in step S2, the dyeing and fixation are performed simultaneously at room temperature.

[0034] In some embodiments of the present invention, in step S2, the dual-reactive dye is a double monochlorotriazine, preferably at least one of AVITERA YELLOW SE, AVITERA RED SE, and AVITERA BLUESE; in other words, the specific type of the three dual-reactive dyes used, or two or all three used together, can be flexibly adjusted according to actual application requirements. The dual-reactive dye, consisting of a dual-reactive group, a monochlorotriazine, or two monofluorotriazine groups connected by a bridging group to form a symmetrical structure, significantly improves the binding stability between the dye and the fiber, making it particularly suitable for textiles requiring high wash fastness.

[0035] In some embodiments of the present invention, in step S2, the compound dyeing substitute alkali is a COLOFOCE DR substitute alkali, preferably free of sodium silicate. By removing silicon and optimizing the alkali formulation, multi-dimensional breakthroughs are achieved in environmental compliance, process stability, dyeing quality, and cost efficiency. It is particularly suitable for current green manufacturing needs and high-quality fabric production. Its core advantages can be summarized as: no silicon pollution, rapid dissolution, stable pH, fiber-friendly, simple post-treatment, and improved fastness. Free of sodium silicate, it avoids the formation of silica scale, requiring only 1-2 neutral washing steps, reducing water consumption to 40-50 L / kg, lowering washing costs by 30%-40%, and simultaneously reducing wastewater treatment load (COD emissions reduced by 30%). The alkaline buffer environment of the compound alkali (replacing caustic soda and sodium silicate water) reduces fiber damage (compared to the strongly alkaline system of caustic soda and sodium silicate) and leaves no rigid residue. When used with softeners, the softener adsorption rate increases by 10-20%, and the fabric hand feel improves from level 2-3 in traditional processes to level 4 or above (the static drape coefficient increases from about 40-50% to below 30% for ultra-soft or even 20% for a super-soft hand feel) (based on subjective touch rating or a fabric drape performance tester). When using a sodium silicate-free compound dyeing alkali substitute, a separate sodium silicate removal process is eliminated, and the stacking time is shortened from the traditional 18-24 hours to 12-18 hours (adjusted depending on the dye type), increasing production efficiency by 20%. This overcomes the bottlenecks of silicon residue and poor hand feel in traditional cold-batch dyeing, combining environmental, cost, and quality advantages.

[0036] In some embodiments of the present invention, in step S2, the pH value of the alkaline buffer environment is 11.5~12.5. The substitute alkali used has good buffering performance, excellent stability and reproducibility, and achieves a high dyeing yield. The present invention employs a green and energy-saving cold pad-batch dyeing process, in which dual-reactive-group dyes and compound alkalis are pad-batch dyeed in a single bath. The compound alkali is a concentrated buffer alkali, scientifically compounded with multiple alkali agents (sodium hydroxide, sodium carbonate, sodium bicarbonate, organic amine compounds) and buffers (citrate, phosphate) to construct a pH-stable alkaline environment, replacing traditional caustic soda and sodium silicate. During the pad-batch process, the compound alkali maintains a stable pH range of 11.5~12.5 (i.e., 12±0.5) (compared to the traditional sodium silicate system). The pH range is ±0.5, ensuring that the reactive dyes react fully with the fibers, increasing the fixation rate by 5%~10% and reducing the residue of unfixed dyes; the padding liquor ratio is 55~70% (depending on the type of fabric), which is less than the traditional roll dyeing liquor ratio of 1:3~10, resulting in less dye liquor consumption, significantly less residual dye liquor and residual liquor, less water consumption for washing, and better efficiency and fastness; this process is room temperature dyeing, requiring no heat energy, and greatly reduces electricity and steam energy consumption by 50%~80% compared to the high-temperature dyeing of traditional roll dyeing, pad dyeing, and hot melt dyeing.

[0037] In some embodiments of the present invention, in step S3, the pH value of the acidic condition is 2-3, and the temperature is 98±2℃. Under acidic conditions, combined with a compound fiber bulking agent, the fibers can be effectively separated and fluffed, resulting in a velvety texture.

[0038] In some embodiments of the present invention, in step S3, the aperture of the mechanical grid device impacting the fibers is 5-8 mm, and the spacing is 5-8 cm. The water flow washing is carried out in a completely loose, new wide-width device. Through the synergistic effect of "chemical expansion-physical impact-flow field loosening," the fibers are radially expanded and softened in an acidic, high-temperature environment. Combined with the impact of the mechanical grid device in the liquid loose device and the gas-liquid two-phase impact, micron-sized fibers with a diameter of 5-10 μm and a length of 50-100 μm can be controllably generated. This solves the pain points of traditional napping (coarse fibers) and chemical fiber opening (high cost and pollution). The main methods are: 1. Fiber expansion modification: A compound expansion agent (organic acid + polar) is used to break the hydrogen bonds in the fibers under pH 2-3 and a temperature of 98±2℃, making the Lyocell cotton... 1. Fiber radial expansion rate reaches 15%~20%, and the surface skin softens and is easy to peel off; 2. Loose flow field impact: In a liquid environment, the fabric reciprocates and impacts the mechanical grid (pore size 5~8mm, spacing 5~8cm) at a speed of 0.3~0.5m / s, while simultaneously withstanding the impact of a gas-liquid mixture flow (water pressure 0.2~0.3MPa, wind speed 45~55m / s) with 50% flow rate above and below, achieving tension-free loosening; 3. Pile directional peeling: The expanded fiber skin peels off layer by layer under the action of impact and scouring, forming fine pile with a tip diameter <10μm, while the root retains the complete fiber structure (strength retention rate ≥90%).

[0039] In some embodiments of the present invention, in step S3, the loose flow field impact is carried out by a gas-liquid mixture with 50% flow rate at the top and bottom, preferably with a water pressure of 0.2~0.3MPa and a wind speed of 45~55m / s; under the action of a certain pressure and wind speed of the water and air mixture, the fibers are split.

[0040] In some embodiments of the present invention, in step S3, the fiber swelling agent is DIADAVIN®S0125, which is an organic acid agent that can increase the loose and dense fibrillation of fibers to obtain a peach skin velvet style.

[0041] In some embodiments of the present invention, in step S3, the pH value of the acidic high-temperature condition is 2~3, and the temperature is 98±2℃; high temperature and acidic conditions help with fibrillation and fibrillation.

[0042] In some embodiments of the present invention, in step S4, the neutral cellulase is NeuPolish8000L. It polishes the split or fibrillated fibers, resulting in a smooth, comfortable, and non-irritating feel with a soft, plush texture.

[0043] In some embodiments of the present invention, in step S4, the smoothing agent in the bath is PERSOFTAL® L02, which plays a smoothing role and prevents the fabric surface from being scratched or damaged by water rinsing.

[0044] In some embodiments of the present invention, in step S5, the polyether-modified silicone oil is a TDS-hydrophilic softener. The hydrophilic softener, in combination with the nano-microcapsule softener, forms a surface lubricating film and an internal slow-release structure, thereby achieving excellent hydrophilicity, washability, and a soft, supple feel, resulting in a durable, hydrophilic, and ultra-soft fabric.

[0045] In some embodiments of the present invention, in step S5, the nano-microcapsule softener is Gernro M-TEC. The combination of a hydrophilic softener and a nano-microcapsule softener achieves excellent hydrophilicity, wash resistance, and a soft, supple feel; the amount used can be increased or decreased according to the customer's desired feel.

[0046] In some embodiments of the present invention, in step S5, the amount of polyether-modified silicone oil used is 15~30 g / L.

[0047] In some embodiments of the present invention, in step S5, the amount of the nano-microcapsule softener is 5~20g / L.

[0048] In some embodiments of the present invention, in step S5, the product is dried after impregnation under conditions of pH 5.5 to 7.0. The acidic condition is to neutralize the residual alkali in the semi-finished product, so that the finished product meets the pH range required by national or industry standards. The specific dosage is adjusted by technicians according to the pH value of each order.

[0049] In some embodiments of the present invention, in step S5, the drying temperature is 140±5℃ and the drying time is 40s. Baking serves as a cross-linking reaction, and the process temperature is slightly lower than that of conventional finishing (160~170℃) to prevent hardening of the hand feel.

[0050] In some embodiments of the present invention, in step S6, the humidity of the humid and hot steam environment is 75-85%, and the temperature is 100-110°C. This is beneficial for eliminating internal stress in the fabric, improving the feel, and achieving a pre-shrinking effect; the optimal humidity and temperature in equipment production practice can better achieve a good feel and pre-shrinking effect.

[0051] In some embodiments of the present invention, in step S6, the pressure applied to the rubber blanket or felt blanket is 0.4~0.6 mar, which can better achieve a good hand feel and pre-shrinking effect.

[0052] Example 1 This embodiment uses 80s / 60s Lyocell cotton satin fabric as an example. The dyeing and finishing process is as follows: 1. Singeing: Using an OSTOFF OS07-4 device, after singeing, desizing with a compound enzyme for 8 hours, with an enzyme dosage of 6g / L, a penetrant dosage of 3g / L, and a complexing agent dosage of 3g / L; 2. Cold Batch Dyeing: With a 70% liquor ratio, batching at room temperature for 18-22 hours, with a dye dosage of 5g / L and a compound dyeing alkali substitute of 30g / L; 3. Soft Washing: With a pH of 2-3, treatment at 98℃ for 30 minutes, using DIADAVIN®S0125 swelling agent 6g / L and acetic acid 3g / L, with the equipment... 4. Enzyme washing: Use NeuPolish 8000L enzyme preparation 10g / L, bath smoothing agent 10g / L, temperature 50℃, treat for 30 minutes, then raise the temperature to 80℃ to deactivate, add soda ash; 5. Softening finishing: Polyether silicone oil 20g / L + nano-microcapsule silicone oil 20g / L, drying temperature 140℃, time 50s; 6. Shrinkage: Steam conditions 110℃, machine speed 50m / min, use rubber blanket to provide compression and rebound force.

[0053] Example 2 1. Instruments and equipment: singeing machine, dyeing machine, water flow washing machine, setting machine, calendering machine, shrinking machine.

[0054] 2. Fabric selection: Select Lyocell cotton fabrics with different yarn counts and densities to determine the range of fabrics applicable to the dyeing and finishing process provided by this invention, as shown in Table 1.

[0055] Table 1. Fabric types of different models

[0056] 3. Selection of dyeing and finishing processes: This invention provides a dyeing and finishing process, including the following process flow: Dyeing and printing process flow: singeing (enzyme pile) → washing → cold pile dyeing → washing → gentle washing (water flow gentle washing + enzyme gentle washing) → softening → calendering → shrinkage.

[0057] 3.1 Singeing and Stacking: Table 2. Types, Dosage, and Units of Enzyme Accumulation Preparations

[0058] The singeing process was carried out on an OTHOFF OS07-4 singeing machine from Germany, followed by 8 hours of resting at room temperature. The composite enzyme preparation used in this invention is a complex enzyme composed of amylase, saccharifying enzyme, and cellulase, designed to degrade different slurries. Specifically, the composite enzyme preparation is model T5050, purchased from Qingdao Kecheng Chemical Co., Ltd.; the penetrant is model DX-6100A, purchased from Qingdao Fukai Rubber & Plastic New Materials Co., Ltd.; and the dispersing and complexing agent is model TX-6508, purchased from Yantai Yuanming Chemical Co., Ltd.

[0059] 3.2 Cold pile staining: Table 3. Types, Dosage, and Units of Cold-Built Dyeing Agents

[0060] The cold-batch dyeing process is conducted at room temperature, with padding and rolling at a speed of 60-80 m / min. The padding machine utilizes a German Köst uniform padding system, achieving a padding rate of 50-80%, with a minimum of 50%. After dyeing, the dyed fabric is stored at room temperature in an insulated shed for 18-22 hours. The cold-batch dyeing compound dyeing alkali used here is sodium silicate-free. By removing silicon and optimizing the alkali formulation, it achieves breakthroughs in environmental compliance, process stability, dyeing quality, and cost efficiency. It is particularly suitable for current green manufacturing needs and high-quality fabric production. Its core advantages can be summarized as: no silicon pollution, rapid dissolution, stable pH, fiber-friendly, simple post-treatment, and improved fastness. The dual-reactive dyes are selected from Huntsman Chemical Trading (Shanghai) Co., Ltd., and the compound dyeing alkali is selected from Jiangsu Xinruibei Technology Co., Ltd.'s COLOFOCE DR alkali substitute.

[0061] 3.3 Gentle water wash: Table 4. Types, dosages, and units of preparations used in water-based rinsing.

[0062] The equipment's process flow consists of: fabric feeding → wet soft washing (loose type) → water washing; machine process parameters: in the loose washing unit, the temperature is 98±2℃, the machine speed is 10m / min, the fabric capacity is 300m, and the pH value is controlled between 2 and 3; the temperature of the subsequent water washing tank is 80±2℃; under wet conditions, through external mechanical and water flow impact, coupled with the chemical action of fiber expanding agents, the fiber surface nap is highlighted, significantly improving the fabric's fluffiness, breathability, and softness in the semi-finished product stage. It is worth noting that the temperatures of the loose washing unit and the subsequent water washing tank may exhibit acceptable errors within a certain range due to the equipment's temperature control in actual operation.

[0063] The specific model of the fiber expanding agent is DIADAVIN®S0125, which was purchased from Tuona Trading (Shanghai) Co., Ltd.

[0064] 3.4 Enzyme preparation for gentle washing: Table 5. Types, dosages, and units of enzyme preparations used in enzyme washes.

[0065] Enzyme inactivation: Table 6. Types, dosages, and units of reagents used in the enzyme inactivation process.

[0066] The process of this unit consists of: fabric feeding → bio-enzyme cleaning and softening treatment → deactivation → water washing.

[0067] The biological enzyme preparation was selected from Genentech neutral cellulase and provided by Qingdao Rhein Textile Materials Co., Ltd.

[0068] The enzyme washing process is carried out on a roll dyeing machine. The processing conditions are: temperature 50℃, speed 80m / min for 6 passes, then the temperature is raised to 80℃, speed 80m / min for 3 passes. Soda ash is added during this process to deactivate the enzyme and prevent side effects caused by enzyme residue in subsequent processes (such as continued hydrolysis of fibers during storage leading to reduced strength).

[0069] The specific model of the bio-enzyme preparation is NeuPolish 8000L, purchased from Novozymes (China) Biotechnology Co., Ltd.; the specific model of the bath smoothing agent is PERSOFTAL®L02 from Tona Trading (Shanghai) Co., Ltd.

[0070] 3.5 Softening Finish: Table 7. Types, dosages, and units of preparations used in the softening process.

[0071] The softening process is completed on a Korean styling and setting machine.

[0072] Softening finishing process conditions: A. Compound solution preparation temperature 40~50℃, stirring speed 200~300rpm. This mainly promotes microcapsule dispersion and avoids high-temperature failure of polyether silicone oil (temperature resistance ≤120℃); B. Pick-up rate 60%~80% to ensure uniform adsorption; C. Drying temperature 140℃, time 50s to prevent premature rupture of microcapsules at high temperatures and ensure retention of sustained-release function; D. No high-temperature setting required, natural cooling prevents excessive cross-linking of silicone oil leading to a stiff feel. The compounding of polyether modified silicone oil and nano-microcapsule softener achieves an enhanced ultra-soft feel, durability, and multifunctionality of the fabric through the synergistic effect of the two functional components.

[0073] The polyether-modified silicone oil, specifically model TDS-hydrophilic softener, was purchased from Shandong Zibo Lurui Fine Chemical Co., Ltd.; the nano-microcapsule silicone oil, specifically model Gernro M-TEC, was purchased from Baoding Green Textile Chemical Co., Ltd.; the penetrant, specifically model DX-6100A, was purchased from Qingdao Fukai Rubber & Plastic New Materials Co., Ltd.; and the color-fixing agent, specifically model ERIONAL® PCL, was purchased from Huntsman Group. The amount of color-fixing agent used can be determined according to the depth of color.

[0074] 3.6 Shrinkage: Process conditions: 50±5 m / min; drum heating steam pressure: 0.4~0.6 Mar, temperature: 110℃.

[0075] Test results show that the fabric produced using this process has good lint removal properties, softness, washability, color fastness, and breathability, which can meet the demand of the high-end home textile market for high-count fleece-feel fabrics.

[0076] See Figure 1 The brushed fabric provided by the prior art presents loose and broken yarns, while the soft fabric obtained by the process provided by the present invention has a loose and broken yarn form.

[0077] See Figure 2 Existing brushed fabrics often have a lot of broken fibers on their surface, while the soft fabric obtained by the process provided by this invention has no obvious broken fibers on its surface. Furthermore, the fibers are fluffy and contain a small amount of downy fibers.

[0078] See Figure 3 Existing brushed fabrics have a lot of broken fibers on their surface, while the soft fabric obtained by the process provided by this invention has a small amount of fiber feathers.

[0079] Furthermore, the shedding rate of the fabric obtained in Example 2, as measured by FZ / T62030, was only 0.22%; the dry rubbing color fastness of the fabric obtained in Example 2, as measured by GB / T3920, was grade 4 for both dry and wet rubbing; the acid staining color fastness of the fabric obtained in Example 2, as measured by GB / T3922, was grade 4 for both acid staining and alkali staining; the light fastness of the fabric obtained in Example 2, as measured by GB / T8427, was grade 4 for both color change and staining; and the strip method of GB / T3923.1 was used to measure the color fastness of the fabric obtained in Example 2. The breaking strength of the fabric obtained in Example 2 is as follows: the warp breaking strength is 509 N, and the weft breaking strength is 277 N. The tearing strength of the fabric obtained in Example 2 was measured using the pendulum method according to GB / T 3917.1, with the warp strength greater than 16 N and the weft strength 11 N. The pilling resistance of the fabric obtained in Example 2 was measured using GB / T 4802.2, with a pilling grade of 4 and a shedding performance grade of 3. The fabric density of the fabric obtained in Example 2 was measured to be 185*120 according to GB / T 4669. The fabric weight of the fabric obtained in Example 2 was measured to be 118 g / m² according to ISO 7211-2. 2 The fabric drape of the fabric obtained in Example 2 was measured according to GB / T23329-2009, with a static drape coefficient of 19.22% and a shape change rate of 209.72%. The pH value of the fabric obtained in Example 2 was measured to be 6.46 according to GB / T7573. The free formaldehyde content of the fabric obtained in Example 2 was measured to be 11 ppm (nd) according to GB / T2912.1. The dimensional stability of the fabric obtained in Example 2 after washing was measured according to GB / T8628-8630, with a warp shrinkage rate of -2.73% and a weft shrinkage rate of -3.0%.

[0080] In addition, essentially the same as Example 2, Example 3 was implemented in this invention, and the fabric obtained in Example 3 was subjected to performance testing as described above. The test results are as follows: The color fastness to rubbing of the fabric obtained in Example 3 was measured according to GB / T3920, with a dry rubbing grade of 4 and a wet rubbing grade of 4; the color fastness to soaping of the fabric obtained in Example 3 was measured according to GB / T3921.3, with a color change grade of 4 and a staining grade of 4; the color fastness to perspiration of the fabric obtained in Example 3 was measured according to GB / T3922, with an acid color change grade of 4, an acid staining grade of 4, an alkali color change grade of 4, and an alkali staining grade of 4; the color fastness to sunlight of the fabric obtained in Example 3 was measured according to GB / T8427. The color fastness to water is grade 4; according to GB / T5713, the color change grade is grade 4, and the staining grade is grade 4; the breaking strength of the fabric obtained in Example 3 was measured according to the strip method of GB / T3923.1, with a warp breaking strength of 302N and a weft breaking strength of 281N; the tearing strength of the fabric obtained in Example 3 was measured according to the pendulum method of GB / T3917.1, with a warp tearing strength greater than 16N and a weft tearing strength greater than 16N; the anti-pilling performance of the fabric obtained in Example 3 was measured according to GB / T4802.2, with a pilling grade of 4 and a lint removal grade of 3; the lint removal rate of the fabric obtained in Example 3 was measured according to FZ / T62030, which is 0.28%; according to GB / T The fabric density of the fabric obtained in Example 3 was measured to be 241*10⁹ according to 4669; the fabric weight of the fabric obtained in Example 3 was measured to be 142 g / m² according to ISO 7211-2; the fabric drape of the fabric obtained in Example 3 was measured to be 19.11% static drape coefficient, 59.46% dynamic drape coefficient, and morphological change rate of 211.64% according to GB / T 2912.1; the pH value of the fabric obtained in Example 3 was measured to be 6.64 according to GB / T 2912.1; the free formaldehyde content of the fabric obtained in Example 3 was measured to be 8.4 ppm (nd) according to GB / T 2912.1; and the dimensional stability of the fabric obtained in Example 3 after washing was measured to be -3.72% in the warp and -1.7% in the weft according to GB / T 8628-8630.

[0081] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims. Furthermore, specific examples have been used in the specification to illustrate the principles and implementation methods of the present invention. The above description of the embodiments is only for the purpose of helping to understand the method and core ideas of the present invention, and the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A delicate dyeing and finishing process for wide-width woven fabrics used in home textiles, characterized in that, The process includes the following steps: S1 Pretreatment: After singeing the fabric, the fabric is desized by stacking it with a compound enzyme preparation composed of amylase, saccharifying enzyme and cellulase. S2 dyeing: The cold pad-batch dyeing process is adopted, which completes the dyeing and fixing through pad-cold-batch method of dual reactive dyes and compound dyeing substitute alkali, and creates an alkaline buffer environment. After dyeing, the fabric is washed and the pH is neutralized. S3 Water Flow Soft Wash: The fabric obtained in step S2 is placed under acidic conditions and treated with a loose water flow airflow treatment device. Under the conditions of impact from mechanical grid equipment or loose flow field impact from dyeing vat equipment, and in conjunction with a fiber swelling agent, it is treated under acidic high temperature conditions to form soft fluff. S4 Enzyme Soft Wash Treatment: Neutral cellulase and bath smoothing agent are used to remove surface hairs and primary cell walls, forming a soft, hairy feel. The enzyme reaction is controlled by heating and inactivation with soda ash. S5 softening finish: Polyether modified silicone oil and nano-microcapsule softener are compounded, impregnated, dried and baked to form a surface lubricating film and an internal slow-release structure; S6 shrinkage: Controllable shrinkage force is applied in a humid and hot steam environment using rubber or felt blankets to eliminate internal stress.

2. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S1, the singeing process is carried out using a German OTHOFF OS07-4 singeing machine, and the product is stacked at room temperature for 8 to 10 hours. The compound enzyme preparation is compound enzyme preparation T5050; The mass ratio of amylase, saccharifying enzyme and cellulase is 80:5:15; The deslurry removal process was carried out at room temperature.

3. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S2, the cold pad-batch dyeing process uses pad-dyeing compound dyeing as a substitute for alkali. In step S2, the dyeing and fixation are carried out simultaneously at room temperature. In step S2, the dual reactive dye is bis(chlorotriazine), preferably at least one of AVITERA YELLOW SE, AVITERA RED SE, and AVITERA BLUE SE.

4. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S2, the compound dyeing substitute is COLOFOCE DR substitute, and preferably the compound dyeing substitute does not contain sodium silicate. In step S2, the pH value of the alkaline buffer environment is 11.5~12.

5.

5. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S3, the aperture of the mechanical grid device impacts is 5~8mm, and the spacing is 5~8cm; In step S3, the loose flow field impact consists of a gas-liquid mixture with 50% flow rate at the top and bottom, preferably with a water pressure of 0.2~0.3MPa and a wind speed of 45~55m / s.

6. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S3, the fiber expanding agent is DIADAVIN®S0125; In step S3, the pH value of the acidic high-temperature condition is 2~3, and the temperature is 98±2℃.

7. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S4, the neutral cellulase is NeuPolish 8000L; In step S4, the smoothing agent in the bath is PERSOFTAL® L02.

8. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S5, the polyether-modified silicone oil is a TDS-hydrophilic softener; In step S5, the nano-microcapsule softener is Gernro M-TEC; In step S5, the amount of polyether-modified silicone oil used is 15~30g / L.

9. The process according to claim 1, characterized in that, It has at least one of the following characteristics: The amount of the nano-microcapsule softener used is 5~20g / L; In step S5, the product is impregnated and then dried under conditions of pH 5.5 to 7.

0. In step S5, the drying temperature is 140±5℃ and the drying time is 40s.

10. The process according to claim 1, characterized in that, It has at least one of the following characteristics: In step S6, the humidity of the hot and humid steam environment is 75-85%, and the temperature is 100-110℃; in step S6, the pressure applied to the rubber blanket or felt blanket is 0.4-0.6 mm.

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