Preparation method of color automotive interior fabric

Abstract

This application provides a method for preparing colored automotive interior fabric, belonging to the field of high-performance fabric technology. Using PET chips, pigments, dispersants, and auxiliaries as raw materials, PET masterbatch is prepared. The PET chips have an intrinsic viscosity of 0.60~0.75 dL / g, the pigment has a particle size ≤100nm, a temperature resistance ≥280℃, and a mass percentage of 5~60%; the dispersant has a mass percentage of 3~8%; the auxiliaries have a mass percentage of 0.1~8%; and the remainder is PET chips. Using PET and COPET as raw materials, the PET masterbatch is added, and composite spinning is performed to form microfiber colored spun island yarn. The microfiber colored spun island yarn has a fineness of 2~5 dtex. The microfiber colored spun island yarn is woven to obtain a grey fabric, which is then opened, brushed, and fixed to obtain the automotive interior fabric. The automotive interior fabric prepared by this method has advantages such as low monofilament fineness, a feel close to genuine leather, color fastness of not less than grade 4, good physical properties, and low dyeing wastewater discharge.

Description

Technical Field

[0001] This application relates to a method for preparing colored automotive interior fabric, belonging to the field of high-performance fabric technology. Background Technology

[0002] Color-spun ultrafine island-style imitation sheepskin fabric is a high-end textile fabric made from color-spun ultrafine island fibers as the core raw material and processed through special techniques to imitate the appearance, feel, and texture of natural sheepskin.

[0003] However, most suede fabrics currently available are black or gray, dyed using a one-bath disperse dyeing method. This method typically involves first weaving white island fibers into a fabric and then dyeing it. Because the diameter of microfiber after opening is 0.06~0.08 dtex, it requires high-temperature dyeing, which is not only energy-intensive and makes it difficult to dye the fabric brightly, failing to meet consumers' demand for colored fabrics, but also results in poor color fastness to sunlight, with a grade of 2~3, making it difficult to meet the automotive grade 4 requirement. Furthermore, the dyeing process requires reduction washing, which generates a large amount of dyeing wastewater. Summary of the Invention

[0004] In view of this, this application provides a method for preparing colored automotive interior fabric, which not only achieves the molding of fabric with a suede-like texture, but also endows the fabric with good heat-drying performance, high color fastness performance, and bright and colorful colors, which can be applied to current automotive interiors such as headrests, tarpaulins, etc.

[0005] Specifically, this application is implemented through the following scheme: A method for preparing a colored automotive interior fabric, comprising the following steps: Step 1: Using PET chips, pigments, dispersants, and additives as raw materials, PET masterbatch is prepared. The intrinsic viscosity of the PET chips is 0.60~0.75 dL / g. The pigment has a particle size ≤100nm, a temperature resistance ≥280℃, and a mass percentage of 5~15%; the dispersant has a mass percentage of 3~8%; the additives have a mass percentage of 0.1~8%; and the remainder is PET chips. Step 2: Using PET and COPET as raw materials, PET masterbatch is added and composite spinning is carried out to form microfiber colored spun island yarn. The fineness of the microfiber colored spun island yarn is 2~5 dtex. Step 3: The microfiber colored spun island yarn is woven to obtain the greige fabric. The greige fabric is then opened, brushed, and fixed to obtain the colored automotive interior fabric.

[0006] Furthermore, as a preferred option: In step one, The pigment is a mixture of inorganic nano-pigments and organic pigments.

[0007] The dispersant is a polyester dispersant with good compatibility with the PET carrier or a polyolefin wax dispersant that assists in dispersion, such as polyester wax or a superdispersant.

[0008] The additives include lubricants, antioxidants, light stabilizers, and coupling agents. The lubricants are stearic acid, stearate metal salts (zinc stearate, calcium stearate), or polyethylene glycol lubricants. The antioxidants are antioxidant 1010 or antioxidant 168. The coupling agents are silanes or titanates.

[0009] 1. PET Chips: Same as the substrate of the fixed island filament, homopolymer PET chips are preferred, with an intrinsic viscosity of 0.60~0.68dL / g (suitable for the fluidity of the spinning melt), free of impurities and yellowing, ash content ≤0.03%, and moisture content ≤0.02% (pre-drying is required before spinning to avoid melt bubbles affecting the spinning quality); melting point 255~260℃, thermal decomposition temperature ≥300℃, and able to withstand the melt mixing temperature (260~280℃) during the preparation of color masterbatch without degradation or discoloration.

[0010] II. Pigments: Inorganic pigments or high-performance organic pigments are preferred. Dyes that are prone to migration or have poor heat resistance are prohibited (to avoid migration and decomposition during spinning). The thermal decomposition temperature should be ≥300℃, and the pigments should not decompose or change color during masterbatch preparation (260~280℃) and spinning (270~290℃), and should be odorless. The average particle size should be ≤0.1μm, with uniform particle size distribution and no agglomeration (to ensure uniform coloring of the filaments after spinning and avoid color spots and discoloration). The light fastness should be ≥5, and the migration resistance should be ≥4 (suitable for applications such as automotive and home textile island-type filaments, avoiding fading and color migration later). The pigments should not react with PET carriers or dispersion system components and should not affect the fiber opening performance of island-type filaments (not interacting with the marine or island phase components of the island-type filament). The preferred pigments are a mixture of organic and inorganic pigments, with inorganic pigments accounting for 10~40% and organic pigments accounting for 5~20%.

[0011] III. Dispersants: Polyester dispersants or polyolefin wax dispersants that are compatible with PET carriers should be preferred. The dispersants can be adsorbed on the pigment surface, reduce the surface tension of the pigment, break up pigment agglomeration, and make the pigment uniformly dispersed in the PET melt. The thermal decomposition temperature is ≥300℃, which does not affect the spinning temperature and does not produce volatile substances (avoiding the formation of bubbles during spinning). 4. Lubricant: Use stearic acid, metal stearate (zinc stearate, calcium stearate) or polyethylene glycol lubricant; add 0.5-3%.

[0012] V. Antioxidants: Prioritize the use of hindered phenolic primary antioxidants (such as 1010 and 1076) in combination with phosphite auxiliary antioxidants (such as 168) (synergistic effect, improving heat resistance and antioxidant effect); the addition amount is 0.2-1.5%.

[0013] VI. Light stabilizers: Hindered amine (HALS) light stabilizers (such as 944, 770) and ultraviolet absorbers (UVA) (such as 327, 328) are used in combination; the combination ratio is usually HALS:UVA=2:1; the amount added is 0.3-2.0%, more preferably 1.0-2.0%.

[0014] 7. Coupling agent: Silane coupling agents (such as KH550, KH560) or titanate coupling agents suitable for inorganic pigments are selected; the addition amount is 0.1-1.0%. Preferably, when the inorganic pigment addition amount is 20-40%, the coupling agent addition amount is 0.5-1.0%.

[0015] In the above scheme, when preparing color masterbatch, it is advisable to first premix and disperse the pigment with dispersant and coupling agent, and then melt and mix it with PET chips, lubricant, antioxidant and light stabilizer to ensure uniform pigment dispersion.

[0016] All components meet environmental protection requirements, are free of heavy metals (such as lead and cadmium) and harmful volatile substances, and are suitable for high-end applications of island-based filaments (such as automotive and infant home textiles).

[0017] The specific preparation process of PET masterbatch is as follows: PET chips are vacuum dried (e.g., hot air treatment at 80~120℃ for 8~12h) until the water content is ≤30ppm to prevent hydrolysis; pigments and additives are dried to remove water and avoid agglomeration; according to the formula, the treated PET chips, pigments, additives and dispersants are put into a high-speed mixer (preferably at a speed of 1200~1500r / min) and mixed evenly to achieve uniform pre-dispersion of dry powder. After being fed into a twin-screw melt extruder for melt dispersion, the mixture is extruded, cooled and pelletized to obtain PET masterbatch. The temperature of the twin-screw melt extruder is 250~275℃ and the speed is 200~300r / min. The high shear breaks up the pigment agglomerates, dispersing them to below 0.1μm without agglomeration.

[0018] In step two, The microfiber colored spun island-island yarn uses polyester (PET) and PET masterbatch as the island phase and water-soluble polyester (COPET) or low-melting-point alkali-soluble copolymer PET as the sea phase. More preferably, in the island phase, the mass percentage of PET masterbatch is 5-15%. The mass percentage of the island phase is 75-78%, and the mass percentage of the sea phase is 22-25%.

[0019] In the composite spinning process, the island phase and the marine phase are respectively subjected to twin-screw melt extrusion, composite spinning, cooling, oiling, bundling, winding, post-spinning stretching and setting to obtain ultrafiber colored spun island yarn: The metering pump of the twin-screw melt extrusion precisely maintains a stable pressure of 15~20MPa.

[0020] The marine and island phases are individually temperature-controlled to prevent degradation. The island phase is dried to ≤30ppm with an intrinsic viscosity of 0.65~0.75dL / g, and extruded using a screw extruder in three sections: feeding, melting, and homogenizing, with an overall temperature of 260~275℃. The marine phase is dried to ≤30ppm and extruded using a screw extruder in three sections: feeding, melting, and homogenizing, with an overall extrusion temperature of 245~265℃.

[0021] The composite spinneret used in the composite spinneret forming process is of island type or orange petal shape, with 108~288 holes and a single hole flow rate of 0.5~1.0 g / min.

[0022] The cooling process employs side-blowing air, with a wind temperature of 20~25℃, a wind humidity of 65~75%, and a wind speed of 0.4~0.6m / s, allowing the filaments to solidify rapidly.

[0023] The oiling rate is 0.8-1.2%, and it is anti-static and has a clustering effect.

[0024] The winding speed is 1200~2000m / min, resulting in nascent island-of-the-sea yarn with a specification of 1.5~3.0dtex / filament.

[0025] The post-spinning stretching is a multi-stage stretching process with a total stretch ratio of 5.0 to 5.5, resulting in a single filament fineness of 0.08 to 0.12 dtex after post-spinning stretching. The stretching process can be carried out in a steam environment at 70 to 90°C.

[0026] The number of crimps in the monofilament after post-spinning and stretching is about 12~18 per 25m, and the bulkiness is good.

[0027] The shaping process involves treating the product at 120-140℃ for 10-15 minutes to achieve a crystallinity of 28-32%, thus balancing peelability and strength.

[0028] In step three, The weaving is done by machine or warp knitting, and the fabric density is 28-32 threads / cm.

[0029] The fiber opening process employs either alkali reduction fiber opening or hot water fiber opening.

[0030] In the alkali-reduced fiber opening process, the liquor ratio is 1:10~15, and the treatment is carried out at 95~100℃ for 30~60 minutes with NaOH at a concentration of 10~20g / L. The COPET marine phase is hydrolyzed and dissolved, leaving PET ultrafine island fibers with a single filament fineness ≤0.1dtex. The weight loss rate is approximately 22~25%, ensuring complete separation of the marine phase.

[0031] In the hot water fiber opening process, the fabric is treated with hot water at a temperature of 90~98℃ for 30~60 minutes. This method is alkali-free and pollution-free. More preferably, the fabric is treated with hot water at 98℃ for 45 minutes. After treatment, the fabric has a weight loss rate of 23~24%, a single filament fineness of 0.07~0.09 dtex, and a dry rubbing color fastness of grade 3~4.

[0032] The napping process uses a ring napping machine with a belt mesh size of 400-800 and a tension of 0.3-0.4N. The napping is completed in multiple passes (e.g., 3-5 passes) to form a fine nap of 0.5-1.0mm on the surface, giving the fabric a suede-like feel, a soft hand feel, and a matte finish.

[0033] After color fixing, the fabric is placed at 150~160℃ for setting, and the weight of the set fabric is 200~400g / m². 2 The tensile strength is ≥150 N / 5 cm, and the shrinkage rate is ≤3%.

[0034] The process parameters for color fixing are: color fixing temperature 160-175℃, machine speed 10-25m / min, time 40-60s, and overfeed rate 10-15%.

[0035] The color-fixing process includes post-treatment, which employs at least one of softening finishing, waterproof / fouling finishing, and antibacterial flame-retardant finishing. More preferably, the softening finishing uses an amino silicone oil softener, and the waterproof / fouling finishing uses any one of a fluorocarbon treatment agent, an organosilicon treatment agent, etc.

[0036] The brushing and color fixing process also includes a dyeing step for color restoration: using disperse dyes, dyeing for 30-45 minutes at pH 4.5-5.5 and 120-130℃. The disperse dyes are used for high temperature and high pressure (e.g., 0.08MPa when the dye bath temperature is 130℃; 0.12MPa when the dye bath temperature is 135℃) to complete the dyeing.

[0037] After dyeing, reduction cleaning is used to ensure that the washing and rubbing fastness are maintained at level 4 or above.

[0038] The disperse dye is any one of aminoanthraquinones (such as Disperse Red FB, Disperse Blue E-2BL), hydroxyanthraquinones (such as Quinone Ceylan, Disperse Red 60), and polycyclic anthraquinones (such as Anix Black AM-R, Disperse Red FB). The pigment is any one or a complex of several of the following: carbon black, titanium dioxide, iron oxide, cadmium-based pigments, ultramarine, chromium-based pigments, anthraquinones, heterocyclic pigments, and phthalocyanines.

[0039] The above scheme uses pigments and PET to form color masterbatch, and then uses the color masterbatch to composite spin with PET and COPET to obtain island-type microfiber (island microfiber) with a specific island ratio. It not only has good dispersibility and uniformity, but also gives the yarn a stable color effect, so that island microfiber is no longer limited to black, gray and other colors. The obtained yarn is woven into a greige fabric, which is given high heat resistance, dry / wet rubbing color fastness and brightness. The greige fabric can also be further dyed in subsequent processing. This dyeing is a complementary coloring process, which complements the coloring of the island microfiber in the previous molding process to achieve color progression. It is matched with the specific island ratio in the island microfiber to ensure a low color loss rate during the fiber opening process. The wastewater in the greige fabric processing mainly comes from fiber opening, rather than dyeing, and the wastewater volume and cost are significantly controlled. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of this application, 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 some embodiments of this application.

[0041] Figure 1 This is a microstructure diagram of the PET masterbatch from Example 1.

[0042] Figure 2 This is a comparison diagram of the fabrics used in Example 1 and Example 5. Detailed Implementation

[0043] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the technical solutions in the embodiments of this application will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit the technical solutions of this application. All other embodiments obtained by those skilled in the art based on the embodiments in this application without creative effort are within the scope of protection of this application.

[0044] Example 1

[0045] This embodiment provides a method for preparing colored automotive interior fabric. Taking orange headrest fabric as an example, the steps are as follows: Step 1, Production of PET Masterbatch: Using PET chips as raw material and pigments as colorants, a specific dispersion system is introduced, which includes dispersants, lubricants, antioxidants, light stabilizers, and coupling agents.

[0046] The requirements and dosages for each component are as follows: PET chips: Homopolymer PET chips, intrinsic viscosity of approximately 0.68 dL / g, free of impurities and yellowing, ash content ≤0.03%, moisture content ≤0.02%, melting point approximately 255℃, thermal decomposition temperature ≥300℃, can withstand the melt mixing temperature during masterbatch preparation, and will not degrade or discolor, accounting for 62.2% by weight.

[0047] Colorant: Titanium dioxide + transparent red GS (2:1), both with a particle size of 80nm and a mass ratio of 30.0%.

[0048] Dispersant: 691 polyester wax (degradation temperature approximately 360℃), accounting for 5.0% of the total mass.

[0049] Lubricant: calcium stearate, 1.0% by mass.

[0050] Antioxidant: A mixture of antioxidant 1010 and antioxidant 168 (antioxidant 1010: antioxidant 168 = 3:2), accounting for 0.8% of the total mass.

[0051] Light stabilizer: A mixture of light stabilizer 944 and UV absorber 327 (light stabilizer 944: UV absorber 327 = 2:1), accounting for 0.5% of the total mass.

[0052] Coupling agent: silane coupling agent KH550, added at 0.5%.

[0053] S1, PET chips are vacuum hot-air dried until the moisture content is ≤30ppm. The vacuum hot-air drying parameters are set as follows: 110℃ hot air treatment for 10 hours to prevent chip hydrolysis. The remaining material is dried to remove moisture to avoid agglomeration.

[0054] S2. According to the above formula ratio, PET chips, colorant and dispersion system are put into a high-speed mixer and mixed at 1500r / min and 60℃ for about 5 minutes. After the mixture is uniformly mixed and the dry powder is uniformly pre-dispersed, it is sent to a twin-screw melt extruder for melt dispersion.

[0055] S3, the twin-screw melt extruder adopts a co-rotating twin-screw extruder, and the screw length-to-diameter ratio (L / D) is required to be no less than 40. Specifically, in this embodiment, L / D=48. The screw feed section temperature is set to 250℃, the melting section temperature is set to 265℃, the homogenization section temperature is set to 275℃, the die temperature is set to 270℃, and the screw speed is 280r / min. High shear breaks down pigment agglomerates, dispersing them to below 1μm.

[0056] S4, the die head extrudes the strip, cools and pelletizes it to obtain cylindrical particles about 2mm long, which are PET masterbatches.

[0057] The obtained PET masterbatch was tested, and its scanning electron microscope image showed that the particle size was uniform, the pigment did not agglomerate in the PET slice, the melt flow index MFI=23, the color difference value ΔE≤0.5, the temperature resistance ≥280℃, and there was no migration or precipitation.

[0058] Step 2, Preparation of microfiber colored spun island yarn: S1, Raw material preparation: Island phase: PET chips (with parameters consistent with those required in the preparation of PET masterbatch), PET masterbatch, dried to a moisture content of ≤30ppm.

[0059] Marine phase: Water-soluble polyester (COPET, melting point approximately 240–245°C), dried to a moisture content ≤30ppm.

[0060] S2, based on a mass ratio of 75% PET chips + 1% PET masterbatch + 24% COPET, island-phase raw materials and marine-phase raw materials were added separately to a twin-screw melt extruder. The screws for the island-phase and marine-phase raw materials were individually temperature-controlled. For the island-phase raw material, the screw feed section temperature was 260℃, the melt section temperature was 268℃, the homogenization section temperature was 275℃, and the screw speed was 280 r / min. For the marine-phase raw material, the screw feed section temperature was 245℃, the melt section temperature was 255℃, the homogenization section temperature was 265℃, and the screw speed was 280 r / min. The pressure before the metering pump was stabilized at 18.5 MPa. A 24-island spinneret with 108 orifices and a single-orifice flow rate of 0.8 g / min was used. The operating temperature was 25℃ and the relative humidity was RH. After cooling with 65% side blowing air at 0.5 m / s, 0.8% of PET-specific spinning oil (Transfar Chemicals, TF-3680) was applied; the winding speed was 1600 m / min, and the average fineness of the resulting nascent island-of-the-sea yarn was 2.0 dtex / filament.

[0061] S3, Post-spinning stretching: Multi-stage stretching is carried out under steam heating conditions at 85℃, with a total stretch ratio of 5.0. The average fineness of the monofilament after post-spinning stretching is reduced to about 0.10 dtex.

[0062] S4, Curling: Mechanical curling is used, with the number of curls controlled at 15 per 25mm to ensure fluffiness.

[0063] S5, drying and setting: treated at 135℃ for 15 minutes to achieve a crystallinity of 32%, resulting in a superfiber colored spun island yarn that balances peelability and strength.

[0064] The average fineness of the microfiber colored spun island yarn is about 5 dtex, the breaking strength is ≥3.5 cN, and the light fastness reaches level 4 after more than 300 hours (testing standard: QB / T4873-2015 method A2, energy 264kJ).

[0065] Step 3, forming the colored automotive interior fabric: S1 is made from microfiber colored spun island yarn as raw material and is produced by weft knitting. The fabric density is 30 threads / cm.

[0066] S2, Fiber Opening: Alkali-reducing fiber opening was employed at a liquor ratio of 1:10, using 10 g / L NaOH as the alkali agent, and treatment was carried out at 100°C for 40 minutes. During this process, COPET hydrolyzed and dissolved, leaving PET ultrafine island fibers, resulting in a uniform fineness of approximately 0.06–0.08 dtex for the monofilaments in the fabric. The weight loss of the fabric after fiber opening was approximately 24%, and the marine phase was completely separated. During the process of marine phase dissolution and island phase exposure, a small amount of pigment from the islands escaped, which is the main source of wastewater in this case—NaOH and the escaped pigment constitute the main components of the wastewater in this application.

[0067] S3, with the addition of sodium hydrosulfite and other additives for reduction cleaning, the final pH value is about 5, the floating color of the fabric is washed away, and the liquid is drained.

[0068] S4, Drying: Place the fabric at approximately 120°C to dry until thoroughly dry.

[0069] S5, napping: A circular napping machine is used with a 600 mesh belt and a tension of 0.4N. The napping and fuzzing of the fabric after fiber opening is completed in 5 passes, forming a fine nap of about 0.5~1.0mm on the surface, giving the fabric a suede-like feel, soft to the touch, and matte finish.

[0070] S6, Color Fixing in a Setting Machine: The fabric is set at approximately 130°C. The finished product after setting is the automotive interior fabric, denoted as Fabric A. Fabric A has a weight of 300 g / m². 2 Tensile strength ≥350 N / 5 cm, shrinkage rate ±2%.

[0071] Example 2

[0072] This embodiment has the same setup as Embodiment 1, except that the amount of pigment added in step one is different, as shown in Table 1.

[0073] Table 1: Effect of different pigment ratios on the properties of microfiber spun island yarn .

[0074] As shown in Table 1, different ratios, especially the amount of pigment added, affect the performance of microfiber colored spun island yarn as follows: linear density deviation rate gradually increases, linear density CV value gradually increases, breaking strength gradually decreases, breaking strength CV value gradually increases, breaking elongation, breaking elongation CV value, and yarn unevenness CV value gradually increase. It is necessary to optimize the amount of pigment added and auxiliaries according to the "automotive grade" requirements of different application parts.

[0075] Example 3

[0076] This embodiment has the same setup as Embodiment 1, except that the effect of the PET masterbatch ratio in step two is shown in Table 2.

[0077] Table 2: Effect of different PET masterbatch ratios on the performance of a deep orange finished product .

[0078] Table 2 shows that different island-to-island ratios affect the performance of microfiber colored spun island-island yarn as follows: taking 6% deep orange masterbatch as the baseline (relative color yield 90%), as the masterbatch addition increases from 6% to 15%, PET decreases from 70% to 62%, and COPET stabilizes in the 23%–24% range, the fiber color strength increases linearly, while the breaking strength gradually decreases. When 6% to 13% of color masterbatch is added, the color is improved from light orange to dark orange, the relative color yield is increased from 100% to 223.3%, and the tensile strength is reduced from 3.70 cN / dtex to 3.28 cN / dtex. The color and mechanical properties are optimally matched with the requirements of automotive headrests. When 14%–15% of color masterbatch is added, the increase in color yield slows down, and the strength drops to 3.14–3.07 cN / dtex, which is close to the lower limit of spinnability and weaving strength of island yarn.

[0079] Considering the overall coloring effect, mechanical properties, and economy, the recommended masterbatch addition for deep orange solution-dyed island silk is 11%–12%.

[0080] Example 4

[0081] This embodiment has the same setup as Embodiment 1, except that in step three, hot water is used for fiber opening. The fiber is treated with hot water at 98°C for 45 minutes.

[0082] Compared with Example 1, this method is alkali-free, produces less fading, and is pollution-free.

[0083] Example 5

[0084] This embodiment has the same setup as Embodiment 1, except that in step three, a dyeing process is added between the brushing and color fixing steps to replenish the color. S5, napping: A circular napping machine is used with a 600 mesh belt and a tension of 0.4N. The napping and fuzzing of the fabric after fiber opening is completed in 5 passes, forming a fine nap of about 0.5~1.0mm on the surface, giving the fabric a suede-like feel, soft to the touch, and matte finish.

[0085] S6, Dyeing: High-temperature dyeing with disperse dyes is used for color correction. The color difference range is determined by comparing with standard color samples, and the greige fabric is put into a high-temperature and high-pressure overflow dyeing machine; the dye is mixed through the dyeing and chemical conveying system; a dyeing liquor ratio of 1:5 is used, the temperature is raised to 130℃ at 2℃ / min, and held for 40 minutes.

[0086] S7, Color Fixing in a Setting Machine: The fabric after S4 color correction is set at 155℃. The finished product after setting is the colored automotive interior fabric, denoted as Fabric A. Fabric A has a weight of 300g / m². 2 Tensile strength ≥350 N / 5 cm, shrinkage rate ±2%.

[0087] S8, Composite Finishing: Fabric B is obtained by composite sponge, with a weight of 320g / m². 2 Peel strength ≥ 5N / 5cm.

[0088] Throughout the entire processing, the microfiber spun island yarn accounts for nearly 90% of the color yield, while the dyeing process, as a color-correcting step, only accounts for about 10%, significantly reducing the amount of dye used in the dyeing process. Compared to Example 1, Example 5 includes a dyeing process to correct the color of the fabric. The differences in chromaticity between the two are as follows: I. Example 1: Solution-dyed island fiber + alkali reduction / setting machine color fixation 1. Color uniformity (chromaticity / color difference grade) Standard production: ≥4 grade (superior grade requirement).

[0089] Industry internal control: Level 4-5 (good masterbatch dispersion and stable spinning can reach Level 5).

[0090] Standard basis: FZ / T 54099-2018 "Colored Island Polyester Pre-oriented Yarn", color difference grade ≥ 4.

[0091] 2. Colorfastness: Dry friction: ≥4 levels.

[0092] Wet friction: ≥3 levels.

[0093] Water washability: ≥4.

[0094] Sunlight resistance: 3-4 (up to 4 for dark / high-concentration colorants).

[0095] II. Example 5: Solution-dyed island fiber + alkali reduction + touch-up dyeing + color fixation in a setting machine: 1. Color uniformity (chromaticity / color difference grade) Standard finished products: ≥3.5~4 grade.

[0096] Superior grade: ≥ Grade 4.

[0097] Alkali reduction plus re-dyeing will slightly affect uniformity, but qualified products will still remain stable at around level 4.

[0098] 2. Colorfastness (overall improvement) Dry friction: Grade 4-5.

[0099] Wet friction: Grade 3 to 4 (Dark colors ≥ Grade 3).

[0100] Water washability: Grade 4-5.

[0101] Sunlight resistance: Level 4 and above. The combination of re-dyeing dye and original solution coloring stabilizes the sunlight resistance.

[0102] 2) The staining effects of both are as follows: Figure 2 As shown: Fabric A in Example 1 has a relatively soft dyeing, while in Example 5, pigments and disperse dyes are combined to give Fabric B in Example 5 a brighter color.

[0103] Example 6

[0104] This embodiment has the same setup as Embodiment 1, except that in step three, a dyeing process is added between the napping and color fixing processes. Different concentrations of disperse dyes are randomly used for high-temperature dyeing of fabrics with different masterbatch contents. The selection of masterbatch and disperse dyes is shown in Table 3.

[0105] Table 3: Effect of different owf ratios on the color difference ΔE of finished product performance .

[0106] As can be seen from Table 3, good dyeing effect can not be achieved by arbitrarily selecting colorants and disperse dyes. Instead, there is a synergistic effect. Specifically, the dyeing rate of disperse dyes on island silk is about 85%. As long as the fading rate / replenishment owf ≈ 85%, a good dyeing effect can be achieved.

[0107] Comparative Example 1

[0108] Example 2 of CN108867094A is used as Comparative Example 1. Its processing flow is as follows: spinning of brown PA6 / LDPE island-island fibers - production of nonwoven fabric - heat setting - impregnation and curing of polyurethane slurry - heat toluene reduction - napping and softening treatment.

[0109] Comparative Example 2

[0110] Example 1 of CN121205015A is used as Comparative Example 2. The processing flow is as follows: preparation of colored spun ultrafine island fiber - pretreatment, and blending with conventional polyester filament to obtain blended yarn - warp knitting machine weaving - alkali reduction fiber opening - high temperature and high pressure overflow spray dyeing - napping and brushing - softening post-treatment, drying and shaping.

[0111] Table 4: Comparison of Product Performance and Water Consumption for Different Solutions .

[0112] The above scheme uses pigments and PET to form a masterbatch, and then uses the masterbatch and PET as the island phase and COPET as the sea phase for composite spinning to obtain island-type microfiber (island microfiber) with a specific island ratio. This not only has good dispersibility and uniformity, but also gives the yarn a stable color effect, so that island microfiber is no longer limited to dark colors such as black. The obtained yarn is woven into a greige fabric, which is given high heat resistance, dry / wet rubbing color fastness and brightness. The greige fabric can also be further dyed in subsequent processing. This dyeing is a complementary coloring process, which complements the color given by the previous island microfiber molding to achieve color progression. It is matched with the specific island ratio in the island microfiber to ensure a low color loss rate during the fiber opening process. The wastewater in the greige fabric processing mainly comes from fiber opening, rather than dyeing, and the wastewater volume and cost are significantly controlled.

[0113] The above-described embodiments are merely illustrative of several feasible implementations of the present invention, and their descriptions are relatively specific and detailed. However, they should not be construed as limiting the scope of the present invention, nor are the embodiments intended to limit the scope of protection in the claims of the present invention. For those skilled in the art, various modifications and improvements can be made without departing from the concept of the present invention. All equivalent implementations or changes that do not depart from the present invention should be included in the technology of the present invention.

Claims

1. A method for preparing a colored automotive interior fabric, characterized in that, The steps are as follows: Step 1: Using PET chips, pigments, dispersants, and additives as raw materials, PET masterbatch is prepared. The intrinsic viscosity of the PET chips is 0.60~0.75 dL / g. The pigment has a particle size ≤100nm, a temperature resistance ≥280℃, and a mass percentage of 5~15%; the dispersant has a mass percentage of 3~8%; the additives have a mass percentage of 0.1~8%, including at least one of lubricant, antioxidant, light stabilizer and coupling agent; the balance is PET chips; Step 2: Using PET and COPET as raw materials, PET masterbatch is added and composite spinning is carried out to form microfiber colored spun island yarn. The fineness of the microfiber colored spun island yarn is 2~5 dtex. Step 3: The microfiber colored spun island yarn is woven to obtain the greige fabric. The greige fabric is then opened, brushed, and dyed to obtain the automotive interior fabric.

2. The method for preparing a colored automotive interior fabric according to claim 1, characterized in that: In step one, after the raw materials are mixed evenly, they are fed into a twin-screw melt extruder for melting and dispersion, and then extruded, cooled, and pelletized to obtain PET masterbatch. The temperature of the twin-screw melt extruder is 250~275℃ and the rotation speed is 200~300r / min.

3. The method for preparing a colored automotive interior fabric according to claim 1, characterized in that: In step two, PET and PET masterbatch are used as island phases and COPET is used as sea phases. In the composite spinning process, the mass ratio of island phases is 75-78%, and the screw extrusion temperature is 260-275℃; the mass ratio of sea phases is 22-25%, and the screw extrusion temperature is 245-265℃.

4. The method for preparing a colored automotive interior fabric according to claim 1, characterized in that: The composite spinning process includes multi-stage drawing, with a total draw ratio of 5.0 to 5.

5.

5. The method for preparing a colored automotive interior fabric according to claim 1, characterized in that: The fiber opening is performed using either alkali reduction fiber opening or hot water fiber opening. In the alkali reduction fiber opening, the bath ratio is 1:10~15, and the solution is treated with NaOH at a concentration of 10~20g / L at 95~100℃ for 30~60min. In the hot water fiber opening, the solution is treated with hot water at a temperature of 90~98℃ for 30~60min.

6. The method for preparing a colored automotive interior fabric according to claim 1, characterized in that: After color fixing, the fabric is placed at 150~160℃ for setting, and the weight of the set fabric is 200~400g / m². 2 The tensile strength is ≥150 N / 5 cm, and the shrinkage rate is ≤3%.

7. The method for preparing a colored automotive interior fabric according to claim 1, characterized in that: After color fixing, there is also a finishing process, which is at least one of softening finishing, waterproof / stain-resistant finishing, and antibacterial and flame-retardant finishing.

8. A method for preparing a colored automotive interior fabric according to any one of claims 1 to 7, characterized in that, The brushing and color fixing process also includes a dyeing step: using disperse dyes, dyeing for 30-45 minutes at pH 4.5-5.5 and 130-135℃.

9. The method for preparing a colored automotive interior fabric according to claim 8, characterized in that: The disperse dye is any one of aminoanthraquinone, hydroxyanthraquinone, or polycyclic anthraquinone. The pigment is a mixture of inorganic and organic pigments. The inorganic pigment is at least one of carbon black, titanium dioxide, iron oxide, cadmium-based pigments, ultramarine, or chromium-based pigments. The organic pigment is at least one of anthraquinone, heterocyclic, or phthalocyanine pigments.

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