Production method of polyester velvet fabric with ecological discharge printing effect

Abstract

The invention discloses a production method of a polyester velvet fabric with an ecological discharge printing effect, which comprises the following steps: firstly, heating and melting paraffin, beewax, rosin and an auxiliary additive to prepare a wax liquid, and uniformly waxing the polyester velvet fabric in a set pattern area; then, the wax liquid is rapidly stabilized through cold air solidification, diffusion of the wax liquid in the high-plush structure is inhibited, and therefore a clear pattern boundary is formed. After padding dyeing and high-temperature color fixing treatment, the ground color of the fabric is uniform, the pattern area is not colored or is light in color due to the dye-resistant effect, finally, wax is eluted through hot water, flooding is removed, and aftertreatment of the fabric is completed. By means of the method, the layering sense and definition of the pattern effect are improved, meanwhile, the hand feeling and rebound resilience of the fabric are improved, the pollution problem in a traditional dyeing method is avoided, and high production stability and finished product quality are achieved.

Description

Technical Field

[0001] This invention relates to the field of textile printing and dyeing, and more specifically to a method for producing polyester fleece fabrics with an eco-friendly engraving effect. Background Technology

[0002] In the dyeing and pattern printing process of polyester fleece fabrics, traditional pattern formation methods mainly rely on chemical engraving or discharge dyeing techniques. These methods achieve pattern formation through chemical reagents or physical masking, but they often have some problems, such as unclear pattern edges, insufficient pattern layering, and uneven dyeing. At the same time, traditional methods also require complex template design, chemical treatment, and high-temperature and high-pressure operations, resulting in low production efficiency, high costs, serious environmental pollution, and difficulty in guaranteeing the hand feel and resilience of the finished fabric.

[0003] A common drawback of chemical printing and discharge dyeing is that these processes often require the use of chemicals to prevent dye penetration into specific areas. These chemicals can not only pollute the environment but also damage the fabric, especially when processing fleece fabrics, leading to problems such as unclear pattern boundaries and uneven dyeing. Furthermore, traditional heat treatment and washing processes cannot effectively remove residual chemicals from the fabric, resulting in poor hand feel and resilience.

[0004] To address the aforementioned issues, physical resist-dyeing methods have emerged in the production of polyester fleece fabrics. These methods use physical means (such as waxing) to form a resist barrier on the fabric, preventing dye penetration and thus creating a clear pattern. However, existing physical resist-dyeing methods still face problems such as blurred pattern edges, insufficient layering, and unsatisfactory fabric post-processing results. Specifically, ensuring clear fabric patterns, uniform color, and maintaining the fabric's feel and resilience during the resist coating curing, dyeing, dewaxing, and washing processes remains a current technological challenge. Summary of the Invention

[0005] This invention provides a method for producing polyester fleece fabrics with an eco-friendly engraving effect. Through an integrated process of "waxing - rapid solidification - dyeing and fixing - hot washing and dewaxing", a stable physical anti-dyeing barrier is formed in the nape area of ​​the polyester fleece fabric. During the dyeing stage, the pattern area and the background color area are clearly distinguished, overcoming the defects of traditional methods and obtaining an engraving effect with clear edges and distinct layers.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A method for producing polyester fleece fabric with an eco-friendly engraving effect includes the following steps:

[0008] (1) Preparation of wax liquid: The components containing paraffin wax, beeswax and rosin are heated, melted and mixed evenly to obtain wax liquid;

[0009] (2) Waxing: Adjust the angle and gap of the waxing knife so that the polyester fleece fabric passes through the wax liquid with the nap side down, and make the wax liquid evenly adhere to the preset pattern area.

[0010] (3) Cold air solidification: Immediately after waxing, use cold air to blow from the back of the fabric to the front, so that the wax liquid adhering to the tips of the fibers solidifies quickly in the pattern area.

[0011] (4) Dyeing and color fixing: The fabric treated in step (3) is dipped and dyed, and then put into a steamer for color fixing;

[0012] (5) Washing and dewaxing: Wash the fabric in hot water on the flat side after color fixing to remove wax and loose color;

[0013] (6) Dehydration and drying: The washed fabric is dehydrated and dried in an open pattern to obtain a polyester fleece fabric with an imitation engraved pattern.

[0014] In one specific embodiment, the wax liquid in step (1) further comprises stearic acid and an emulsifier.

[0015] In one specific embodiment, the mass ratio of paraffin wax, beeswax, rosin, stearic acid, and emulsifier in the wax liquid is 85:8:4:0.3:0.2.

[0016] In a specific embodiment, in step (1), the components are heated to 85°C to melt and mix evenly to form a wax liquid.

[0017] In a specific embodiment, the fabric described in step (2) is waxed with wax liquid at a speed of 30 m / min.

[0018] In a specific embodiment, the pressure of the cold air in step (3) is 0.5 MPa, and the wax solidifies within 2 to 3 seconds.

[0019] In a specific embodiment, the padding dyeing in step (4) adopts a one-dip-one-roll process with a rolling pressure of 4 kPa and a roll residue rate of 65%.

[0020] In a specific embodiment, the color fixing in step (4) is carried out in a steam oven at 180°C for 90 seconds, and the bottom of the steam oven is provided with a recycling device for collecting dripping wax.

[0021] In a specific embodiment, step (5) involves a three-bath flat-width hot water wash at 95°C, with fabric softener added in the last bath.

[0022] In a specific embodiment, in step (6), the water is dehydrated at 1000 rpm for 10 minutes, followed by open-width drying.

[0023] This method employs a process of "waxing—rapid solidification—dyeing and color fixing—hot washing and dewaxing" to form a stable and controllable physical resist barrier in the napped area of ​​polyester fleece fabrics. This creates a clear color difference between the patterned area and the base color area during the dyeing stage, resulting in a sharp, layered, imitation engraving effect. The paraffin / beeswax / rosin formulation, combined with stearic acid and emulsifiers, is melted and mixed at 85℃, balancing fluidity and film / droplet stability. This allows the wax liquid to adhere evenly and quantitatively to the pre-set patterned area under controlled angle and gap of the waxing knife. A continuous waxing cycle of 30 m / min enables stable mass production. After waxing, 0.5 MPa cold air is blown from the back to the front and applied within 2-3 seconds. Complete solidification significantly inhibits the diffusion and penetration of wax in the high-pile structure and the "bleeding" of pattern boundaries, improving the whiteness of white or light-colored areas and the fineness of pattern outlines. The subsequent combination of one dip and one roll followed by 90 seconds of color fixing in a 180℃ steam oven ensures sufficient dyeing of the base color and stable color fastness. At the same time, the dripping wax recovery device at the bottom of the steam oven reduces wax consumption and pollution. The 95℃ three-bath flat-width hot water wash thoroughly dewaxes and effectively removes floating color. The addition of a softener in the final bath improves the hand feel and resilience of the pile fabric. Combined with 10 minutes of dehydration at 1000 rpm and open-width drying, the drying time is shortened and the risk of deformation and color variation after washing is reduced. Ultimately, while ensuring the consistency of pattern effect, production stability, material utilization, and finished product quality are improved. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the production steps of a polyester fleece fabric with an eco-friendly engraving effect in Example 1.

[0026] Figure 2 This is a schematic diagram of the waxing process in Example 1. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below 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.

[0028] Example 1

[0029] The following detailed description of the implementation process of "a method for producing polyester fleece fabric with an eco-friendly engraving effect" is based on a specific embodiment. The equipment used in this embodiment is a continuous finishing production line, which includes, in sequence, a wax melting and stirring system, a waxing unit (wax tank + wax dipping knife), a cold air coagulation unit, a pad dyeing unit, a steam oven color fixing unit, a three-tank flat-width hot water washing unit, a dehydration unit, and an open-width drying unit.

[0030] Example 1: Preparation of striped pattern imitation engraved polyester fleece fabric

[0031] Choose polyester fleece fabric, for example, with a weight of approximately 300–1000 g / m². 2 Common polyester fleece fabrics with a pile height of approximately 5-50mm are acceptable. The greige fabric is introduced into this process after routine cleaning. The cleaning treatment can adopt conventional dust removal / light washing methods in the art to reduce the impact of floating dust on the uniformity of waxing; this treatment does not constitute a substantial limitation on the steps of this method.

[0032] Weigh the following components by weight: 85 parts paraffin wax, 8 parts beeswax, 4 parts rosin, 0.3 parts stearic acid, and 0.2 parts emulsifier. Add the above components to a wax melting tank equipped with a jacketed heater and mechanical stirrer. Start stirring and raise the temperature to 85°C and maintain it until all components are completely melted. Continue stirring for 10–20 minutes until the mixture is homogeneous, obtaining a wax liquid. To avoid air bubbles causing defects at the edges of the pattern, allow the mixture to stand at 85°C for 3–10 minutes to remove air bubbles, or use conventional low-speed stirring / vacuum degassing methods to ensure the wax liquid is homogeneous and free of obvious air bubbles before transferring it to a wax tank for later use.

[0033] Maintain the temperature of the wax bath at around 85℃ to ensure stable flow of the wax liquid. Adjust the angle and gap of the waxing blade so that the fabric enters the waxing area with the napped side facing down, and apply the wax by passing through the wax liquid at a linear speed of 30m / min.

[0034] To achieve the "preset pattern area", this embodiment adopts a segmented adjustable wax-dipped knife structure along the width direction: the wax-dipped knife is divided into several independent adjustable gap sections in the width direction. Different blade gaps and contact pressures are set for different sections, so that some sections allow wax to remain in the tip area to form a waxed area, while the remaining sections use smaller gaps and larger scraping action to basically scrape away the wax to form an unwaxed area, thereby forming a strip-shaped or block-shaped pattern distribution in the width direction.

[0035] The angle of the wax-dipping knife can be adjusted, for example, within the tilt range of 30° to 60°. The blade gap can be adjusted to an operable range of 0.1 to 1.0 mm according to the pile density and the light and dark difference of the target pattern, so as to ensure that the wax mainly adheres to the pile tip and the wax amount in the pattern area is stable. Those skilled in the art can determine the appropriate value within the above range through small-scale test runs.

[0036] Immediately after leaving the wax-dipped blade, the fabric enters the cold air coagulation unit. The cold air is blown from the back of the fabric to the front to push and cool the wax at the nap, causing it to solidify rapidly in the patterned area. The cold air pressure is set to 0.5 MPa, and the effective contact time of the fabric in the cold air zone is controlled to be 2–3 seconds, allowing the wax to solidify within 2–3 seconds, forming solid wax droplets and / or a wax film.

[0037] To ensure stable processing time, the length of the cold air solidification zone can be set to approximately 1.0–1.5 m at a linear speed of 30 m / min (approximately 0.5 m / s). The nozzles can be multi-row slits or perforated array nozzles covering the fabric width. The distance from the nozzle to the back of the fabric can be set within a standard range of 20–80 mm. Stable fabric movement is achieved through guide rollers and tension control to prevent pattern jitter or edge blurring. After this step, a continuous or discrete cured wax layer forms at the tips of the patterned area, constituting a physical resist barrier for subsequent dyeing stages.

[0038] The fabric, after being solidified by cold air, enters the pad dyeing unit for a one-dip-one-paste treatment. The dye liquor can be a conventional dyeing system suitable for polyester fibers, such as a disperse dye system and its conventional dispersants / leveling agents, etc. The formula and concentration are determined by the depth of the target base color. This embodiment does not limit the specific formula of the dye liquor.

[0039] The padding pressure is set to 4 kPa, and the padding allowance is controlled at 65% to ensure a stable dye uptake in the base color area. After padding, the fabric immediately enters a steamer for color fixing. The steamer temperature is set to 180℃, and the color fixing time is 90 seconds to complete the color development and fixing process. This ensures that the areas not covered by wax are fully dyed, while the patterned areas covered by wax do not dye or appear light-colored due to the anti-dyeing effect.

[0040] Meanwhile, to reduce wax consumption and facilitate cleaning, a recovery device for collecting dripping wax is installed at the bottom of the steaming box. For example, a heat-resistant collection tank / guide plate is installed at the bottom of the steaming box so that the molten dripping wax is collected into the recovery container. After cooling, the recovered wax can be separated into solid and liquid or filtered and reused.

[0041] After color fixing, the fabric enters a flat-width hot water washing unit for dewaxing and removal of excess dye. This embodiment employs a three-tank continuous flat-width hot water washing process, with the water temperature in each tank controlled at 95℃. The fabric passes through the first, second, and third tanks sequentially, and wringing rollers can be installed between each tank to improve liquid exchange efficiency.

[0042] A softener is added in the final wash to improve the fabric's feel and resilience after dewaxing and removing excess dye. After three washes at 95°C, the wax in the patterned areas is effectively removed, and the excess dye in the base color areas is removed simultaneously, resulting in more stable colors and pattern edges.

[0043] After washing, the fabric enters the dehydration unit and is dehydrated at 1000 rpm for 10 minutes to reduce its moisture content; then it enters the opening drying unit for opening drying. The opening drying temperature, air volume, and time are determined according to the fabric weight and moisture content by conventional methods in the industry, so that the fabric finally reaches the finished product moisture content requirements and maintains a flat width.

[0044] The polyester fleece fabric obtained through the above steps forms a sculpted effect in the pre-designed pattern area, clearly distinguishable from the background color area. The pattern edges are clear and the sense of layering is stable. Because the wax is quickly solidified by back-blowing cold air immediately after waxing, the diffusion and penetration of the wax in the fleece structure is suppressed, and the pattern outline is not prone to smudging. With the combination of padding and fixing parameters and high-temperature fixing conditions, the background color area can be fully dyed and the color fastness is stable. The 95℃ three-bath flat-width hot water washing achieves dewaxing and removal of floating color, and the final bath softening finish improves the hand feel, ultimately obtaining a finished polyester fleece fabric that combines pattern effect and wearability performance.

[0045] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for producing polyester fleece fabric with an eco-friendly engraving effect, characterized in that, Includes the following steps: (1) Preparation of wax liquid: The components containing paraffin wax, beeswax and rosin are heated, melted and mixed evenly to obtain wax liquid; (2) Waxing: Adjust the angle and gap of the waxing knife so that the polyester fleece fabric passes through the wax liquid with the nap side down, and make the wax liquid evenly adhere to the preset pattern area. (3) Cold air solidification: Immediately after waxing, use cold air to blow from the back of the fabric to the front, so that the wax liquid adhering to the tips of the fibers solidifies quickly in the patterned area. (4) Dyeing and color fixing: The fabric treated in step (3) is dipped and dyed, and then put into a steamer for color fixing; (5) Washing and dewaxing: Wash the fabric in hot water on the flat side after color fixing to remove wax and loose color; (6) Dehydration and drying: The washed fabric is dehydrated and then dried to obtain a polyester fleece fabric with an imitation engraved pattern.

2. The method according to claim 1, characterized in that, The wax liquid described in step (1) further comprises stearic acid and emulsifier.

3. The method according to claim 2, characterized in that, The mass ratio of paraffin wax, beeswax, rosin, stearic acid, and emulsifier in the wax liquid is 85:8:4:0.3:0.

2.

4. The method according to any one of claims 1 to 3, characterized in that, In step (1), the components are heated to 85°C to melt and mix evenly to form a wax liquid.

5. The method according to any one of claims 1 to 4, characterized in that, The fabric described in step (2) is waxed by passing it through the wax liquid at a speed of 30 m / min.

6. The method according to any one of claims 1 to 5, characterized in that, The pressure of the cold air in step (3) is 0.5 MPa, and the wax solidifies within 2 to 3 seconds.

7. The method according to any one of claims 1 to 6, characterized in that, The pad-dyeing process described in step (4) uses a one-dip-one-roll process with a rolling pressure of 4 kPa and a roll residue rate of 65%.

8. The method according to claim 7, characterized in that, The color fixing in step (4) is carried out in a steam oven at 180°C for 90 seconds, and a recycling device for collecting dripping wax is provided at the bottom of the steam oven.

9. The method according to any one of claims 1 to 8, characterized in that, In step (5), a three-bath flat-width hot water wash is performed at 95°C, and fabric softener is added in the last bath.

10. The method according to any one of claims 1 to 9, characterized in that, In step (6), the product is dehydrated at 1000 rpm for 10 minutes, followed by open-width drying.

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