A dyeing and finishing method for polyester-coated basalt yarn

Abstract

This invention discloses a dyeing and finishing method for polyester-coated basalt core yarn, which comprises a basalt core material and a polyester coating layer. The method includes: winding the core yarn into a double-tapered dyeing bobbin with a winding density of 0.30-0.40 g / cm³; alternating cyclic degreasing under 30-50℃ and 0.05-0.10 MPa cyclic pressure differential conditions; performing staged temperature-increasing dyeing at 0.7-0.9℃ / min to 58-62℃, 0.9-1.1℃ / min to 88-92℃, and 0.4-0.6℃ / min to 128-132℃, with different cyclic pressure differentials used in the heating and holding stages; and performing reduction washing, neutralization, tension-free hot air drying, and balancing after dyeing. This method can improve the problems of excessive burrs and strong itching sensation on the surface of the dyed core yarn.

Description

Technical Field

[0001] This invention relates to the field of yarn dyeing and finishing technology, specifically to a dyeing and finishing method for polyester-coated basalt core yarn. Background Technology

[0002] Basalt fiber possesses characteristics such as heat resistance, corrosion resistance, and stable mechanical properties, making it promising for applications in functional footwear, apparel, and composite textile materials. To address the issues of brittleness and processing damage that can occur when basalt fiber is directly used in apparel textiles, current technologies typically use basalt fiber as the core material, wrapping it with organic fibers such as polyester to form a core-loaded yarn. This type of core-loaded yarn can, to some extent, balance the functionality of basalt fiber with the dyeability, weavability, and softness of the outer coating fiber, making it suitable for the preparation of functional footwear and apparel materials. However, for core-loaded yarns with a polyester outer coating, current dyeing and finishing methods result in yarns with numerous surface burrs and a strong itchy feeling after dyeing and finishing. Summary of the Invention

[0003] The purpose of this invention is to overcome the above-mentioned defects or problems in the background art and to disclose a dyeing and finishing method for polyester-coated basalt yarn, which, compared with the conventional dyeing and finishing method for polyester-coated basalt yarn packages, can improve the problems of excessive burrs and strong itching on the surface of the yarn after dyeing and finishing.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: At least one embodiment discloses a dyeing and finishing method for polyester-coated basalt core yarn, wherein the polyester-coated basalt core yarn comprises an inner basalt core material and an outer polyester coating layer. The dyeing and finishing method includes the following steps: winding the core yarn into a double-tapered dyeing bobbin, wherein the winding density of the dyeing bobbin is 0.30-0.40 g / cm³; loading the dyeing bobbin into a high-temperature and high-pressure bobbin dyeing device, and performing a pre-treatment for degreasing for 20-30 minutes under 30-50℃ and 0.05-0.10 MPa circulating pressure difference conditions. The pre-treatment for oil removal employs an alternating circulation method, switching between internal and external circulation of the dye liquor. The dyeing cylinders after the pre-treatment are then dyed with disperse dyes. This dyeing process includes a phased heating process: increasing the temperature at 0.7-0.9℃ / min to 58-62℃, at 0.9-1.1℃ / min to 88-92℃, and at 0.4-0.6℃ / min to 128-132℃. The circulating pressure difference during the phased heating process is 0.10-0.20 MPa, and the circulating pressure difference during the holding period at 128-132℃ for 20-60 min is 0.05-0.10 MPa. The entire dyeing process uses the alternating circulation method. After dyeing, the temperature is lowered to 58-62℃ at 1-1.5℃ / min, and the liquor is drained. After draining the dye liquor, the dyeing cylinders undergo reduction cleaning and neutralization treatment. The reduction cleaning is performed at 80-90℃ with a temperature of 0.07-0.15℃ / min. Under MPa cyclic pressure difference, the alternating circulation method is used for 18-22 min; the dyeing cylinders after reduction cleaning and neutralization treatment are dried with tensionless hot air at a temperature of 60-70℃ and a cylinder spacing of 5-8 cm, and then equilibrated for 20-26 h.

[0005] The applicant discovered that for basalt core yarn with a polyester outer layer, existing dyeing and finishing processes typically still follow the high-temperature, high-pressure dyeing process used for conventional polyester packaged yarns. The process design mainly focuses on dyeing uniformity, dye uptake, and color fastness. However, the polyester outer layer undergoes some thermal shrinkage and recovery under high-temperature and humid conditions, while the basalt core material does not experience corresponding thermal shrinkage. When the conventional polyester packaged yarn dyeing and finishing process is directly applied to this type of core yarn, excessively tight winding, excessively strong liquid flow impact, or excessively rapid temperature rise in key temperature zones can easily amplify the length difference between the outer layer and the core material during the dyeing and finishing process, causing the basalt core material to be locally exposed on the yarn surface. Once the basalt core material is exposed, it is more prone to breakage and burr formation during subsequent washing, drying, unwinding, weaving, or wear friction. This not only affects the integrity of the yarn surface but also easily causes a tingling sensation upon contact in the resulting fabrics or shoe uppers. At the same time, conventional processes are insufficient in controlling the looseness and permeability of the packaged structure in the early stage and the stability of the structure after dyeing, and it is also difficult to balance the uniformity of dyeing of the inner and outer layers of the package with the integrity of the core yarn covering structure.

[0006] In the above design, by establishing a continuous process control chain in the stages of package forming, pre-dyeing degreasing, dyeing heating, post-dyeing cleaning and drying balancing, the structural disturbance of the core yarn in the entire package dyeing and finishing process can be controlled in a slow-release manner, thereby reducing the risk of local outward expansion and exposure of basalt core material on the yarn surface.

[0007] In the above design, the core yarn is first wound into a double-tapered dyeing bobbin with a winding density of 0.30-0.40 g / cm³ before dyeing and finishing. Compared with conventional high-density rolls, this is more conducive to maintaining the looseness and permeability of the roll and reducing local compaction, uneven heat transfer and stress concentration caused by excessively tight rolls during high-temperature treatment. This provides a basis for structural stability control in the subsequent dyeing process.

[0008] In the above design, the dyeing process adopts a staged heating method from 60℃, 90℃ to 130℃, especially in the critical thermal response range of 90℃ to 130℃, a slower heating rate is used. Compared with the conventional single-stage rapid heating method, this is more conducive to controlling the heat shrinkage release rhythm of the polyester coating layer in the critical temperature range, avoiding the coating layer shrinking too quickly and causing a sudden increase in the core-sheath length difference, thereby reducing the risk of basalt core material exposure and subsequent breakage.

[0009] The applicant also discovered that even if basic dyeing uniformity can be achieved in high-temperature dyeing of packaged yarns, if the same circulating pressure difference is consistently used during the heating and holding stages, or if only a unidirectional circulation method is used, continuous mechanical impact on the package at high temperatures may still occur, causing uneven stress on both sides of the package and leading to localized loosening of the covering structure. In the above design, by using a higher circulating pressure difference during the heating stage to ensure liquid flow penetration and heat transfer, and reducing the circulating pressure difference during the 130℃ holding stage, combined with alternating switching between inward-to-outward and outward-to-inward circulation, the disturbance to the core yarn structure at high temperatures can be reduced while ensuring dyeing completion, thus better maintaining the integrity of the covering.

[0010] In the above design, the reduction cleaning and neutralization treatment carried out at 80-90℃ after dyeing and draining can remove floating color and residual dye, and restore the surface environment of the yarn to a more stable state. This reduces the possibility that residual chemical components will continue to affect the surface state of the coating layer and subsequent heat finishing behavior, which is beneficial to improving the surface integrity and color stability of the dyed yarn.

[0011] In the above design, by using tension-free hot air drying after dyeing and controlling the bobbin spacing and post-drying balancing time, it is possible to avoid secondary exposure of the core yarn due to additional stretching, local compression or uneven heat dissipation during high-temperature drying. At the same time, it is beneficial to gradually stabilize the structural state and moisture content formed after dyeing, thereby reducing the risk of surface burrs and itching during subsequent unwinding, weaving or use.

[0012] The applicant also discovered that, in existing technologies, pursuing dyeing uniformity solely by increasing dyeing temperature, increasing cycle intensity, or simply extending the holding time, while achieving temporary color consistency in localized situations, is more likely to exacerbate the stress difference between the inner and outer layers of the roll and the imbalance in the shrinkage of the covering layer. In the aforementioned design, this invention does not improve the performance of basalt yarn by simply strengthening a single process, but rather achieves a more stable overall state of the dyed yarn through the continuous coordination of roll looseness control, temperature and pressure slow-release control, and post-dyeing tension-free stability control.

[0013] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in step S1, the winding tension is 5-8 N / tex and the roll taper is 5-7°.

[0014] In the above design, by coordinating and limiting the winding tension and the roll taper, it is possible to ensure the stability of the roll forming while avoiding uneven compaction caused by excessively tight rolls or improper taper angles. This allows the inner and outer layers of the roll to maintain a more consistent state of heating and liquid absorption under the action of subsequent high-temperature liquid flow.

[0015] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in step S2, the pretreatment working solution for degreasing includes 1-3 g / L of nonionic degreasing agent and 0.5-1.5 g / L of penetrant, with a bath ratio of 1:8-1:15.

[0016] In the above design, by removing oil and impurities from the surface of the core yarn before dyeing and ensuring that each layer of the roll has more consistent wettability and heat transfer, the dyeing and finishing deviation caused by local surface condition differences can be reduced, thereby providing more stable initial conditions for subsequent staged temperature-raising dyeing.

[0017] In the dyeing and finishing method disclosed in at least one embodiment, preferably, the alternating circulation mode in steps S2 and S3 is switched between outward circulation within the dye liquor and inward circulation within the dye liquor at a rate of 3-8 min / time.

[0018] In the above design, by controlling the switching cycle of the alternating cycle, the inner and outer sides of the roll can take turns to bear the liquid flow in a short period of time, avoiding the roll being subjected to unilateral impact for a long time, which would cause the local covering structure to loosen, thereby further improving the consistency of the stress on both sides of the core yarn and the dyeing.

[0019] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in step S3, the amount of disperse dye used is 1-5% owf of the yarn mass, 0.5-2 g / L of dispersant and 0.5-1.5 g / L of leveling agent are added to the dyeing working solution, and the pH of the bath solution is adjusted to 4.5-5.5.

[0020] In the above design, by adopting a disperse dyeing system that matches the polyester coating layer and keeping the dye and auxiliaries within a relatively stable ratio range, the heat transfer, dye transfer and coating layer thermal response can be more coordinated, reducing color difference and structural fluctuations caused by inconsistent dyeing rhythms between the inner and outer layers of the package.

[0021] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in step S3, when performing dark dyeing, the holding time at 128-132°C is 45-60 min.

[0022] In the above design, for dark dyeing routes, appropriately extending the heat preservation time at 130℃ is beneficial to improve the dyeing sufficiency of the polyester coating layer. However, the heat preservation time should still be controlled within the above range to avoid further amplification of shrinkage mismatch between the coating layer and the core material due to excessively long high temperature.

[0023] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in step S4, the reducing cleaning agent system includes 1-3 g / L of sodium hydrosulfite and 1-2 g / L of caustic soda, and the neutralization treatment uses organic acid to adjust the pH of the bath solution to 6.5-7.0.

[0024] In the above design, by limiting the reducing cleaning agent system and the neutralization endpoint, it is possible to effectively remove floating color while avoiding excessive treatment or insufficient neutralization from causing additional adverse effects on the surface state of the coating layer, thereby making the subsequent drying and balancing processes more stable.

[0025] In the dyeing and finishing method disclosed in at least one embodiment, preferably, the tensionless hot air drying in step S5 means that no additional stretching tension is applied to the core yarn body during the drying process, and static hot air drying or low torque support is adopted.

[0026] In the above design, by avoiding applying additional stretching tension to the core yarn during the drying process, it is possible to reduce the pulling or misalignment of the already balanced coating structure after dyeing, thereby suppressing the secondary exposure of the basalt core material in the later stage of drying.

[0027] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in step S5, the drying temperature is 60-70°C, the distance between the drying cylinders is 5-8 cm, and the equilibration time is 20-26 h.

[0028] In the above design, by controlling the drying temperature, the distance between the rolls and the balancing time within the above range, the rolls can obtain a more uniform hot air effect and a more sufficient release of the subsequent state, avoiding local poor recovery and structural rebound caused by overly dense or insufficiently balanced rolls during packaging.

[0029] In the dyeing and finishing method disclosed in at least one embodiment, preferably, the cyclic pressure difference during the heating stage in step S3 is 0.14-0.16 MPa, and the cyclic pressure difference during the heat preservation stage at 128-132℃ is 0.06-0.08 MPa.

[0030] In the above design, by adopting the above-mentioned preferred combination of cyclic pressure difference, a better balance can be achieved between ensuring liquid flow penetration during the heating stage and structural slow release during the heat preservation stage, thereby more stably demonstrating the protective effect of the present invention on the core yarn covering structure.

[0031] In the above design, by ensuring that the fabric structure, weight, basalt content, coating layer form, and dyeing route are within a mutually matching range, the thermal response difference between the basalt core material and the coating layer can be controlled within a more easily adjustable range. This avoids amplifying structural imbalance due to excessively high core material ratio, loose structure, or insufficient coating continuity, and thus is more conducive to stably demonstrating the improvement effect of this invention on smoothness and comfort. Attached Figure Description

[0032] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments are briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a flowchart of the dyeing and finishing method for polyester-coated basalt yarn according to an embodiment of the present invention. Detailed Implementation

[0034] 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 preferred embodiments of the present invention and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0035] In the claims, description and accompanying drawings of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."

[0036] This invention relates to a dyeing and finishing method for polyester-coated basalt core yarn, wherein the polyester-coated basalt core yarn includes a basalt core material and a polyester coating layer covering the outer periphery of the basalt core material, as described above. Figure 1 The dyeing and finishing method mainly includes the following steps: S10: The core yarn is wound into a double-tapered dyeing bobbin, wherein the winding density of the dyeing bobbin is 0.30-0.40 g / cm³; S20: The dyeing bobbin is loaded into a high-temperature and high-pressure yarn dyeing equipment and subjected to pre-treatment for degreasing for 20-30 minutes under the conditions of 30-50℃ and 0.05-0.10MPa circulating pressure difference, and an alternating circulation method is adopted. S30: The dyeing cylinder after degreasing pretreatment is dyed with disperse dye. The dyeing includes a staged heating process of increasing the temperature at 0.7-0.9℃ / min to 58-62℃, increasing the temperature at 0.9-1.1℃ / min to 88-92℃, and increasing the temperature at 0.4-0.6℃ / min to 128-132℃, and controlling different circulating pressure differences in the heating stage and the holding stage respectively. S40: After the staining solution is drained, the staining tube is subjected to reduction cleaning and neutralization treatment. The reduction cleaning is carried out in an alternating circulation mode for 18-22 minutes under the conditions of 80-90℃ and 0.07-0.15 MPa circulating pressure difference. S50: The dyeing cylinders after reduction cleaning and neutralization treatment are dried with tensionless hot air, and the drying temperature is controlled at 60-70℃ and the cylinder spacing is 5-8 cm. After drying, the cylinders are equilibrated for 20-26 hours.

[0037] The following is a detailed explanation of each of the above steps.

[0038] The dyeing and finishing method provided by this invention is applicable to the dyeing and finishing of yarn packages with basalt fiber as the core material and polyester filament as the outer covering layer. The yarn package can be used as yarn for weaving or knitting functional shoe upper materials or clothing materials. Disperse dyes suitable for polyester covering layers are preferably used during dyeing. Pretreatment can employ nonionic degreasing agents and penetrants, while post-dyeing treatment can use reducing cleaning agents and organic acid neutralizing agents.

[0039] Step S10 involves using a conical winding device to package the core yarn. Before winding begins, the surface of the core yarn is checked for obvious damage and loose covering, and then the core yarn is continuously fed into the winding station. The preferred packaging method is a double-tapered dyeing bobbin. During winding, the winding density is controlled between 0.30 g / cm³ and 0.40 g / cm³ to maintain good looseness and liquid flow permeability.

[0040] The winding tension is preferably controlled between 5 N / tex and 8 N / tex, and the roll taper is preferably controlled between 5° and 7°. The winding density can be calculated based on the roll mass and roll volume, and the roll taper can be controlled based on the cone angle or the equipment setting. By controlling the winding density, winding tension, and roll taper in a coordinated manner, it is possible to ensure stable roll formation while avoiding uneven stress on the inner and outer layers caused by excessive roll tightness, local compaction, or improper cone angle.

[0041] In one specific embodiment, the core yarn is wound into a double-tapered dyeing bobbin, with the winding density controlled at 0.30 g / cm³, the winding tension controlled at 5 N / tex, and the package taper controlled at 5°.

[0042] Step S20 uses the dyed yarn package obtained in the previous step as the treatment object. The pretreatment for degreasing is carried out using a high-temperature and high-pressure yarn dyeing equipment. Before starting the treatment, treatment water is added to the equipment, and the water temperature is controlled between 30°C and 50°C. Then, nonionic degreasing agent and penetrant are added and circulated and mixed to ensure that the treatment solution is evenly distributed in the equipment.

[0043] After the dyeing cylinder is loaded into the equipment, it undergoes pre-treatment for oil removal under a circulating pressure difference of 0.05 MPa to 0.10 MPa for 20 to 30 minutes. During the oil removal process, an alternating circulation method is used, switching between internal to external circulation and external to internal circulation of the dye liquor. The preferred switching cycle is 3 to 8 minutes per cycle. This method ensures that the inner and outer layers of the cylinder achieve relatively uniform wetting and heat transfer conditions while removing oil and impurities.

[0044] In one specific embodiment, 2 g / L of nonionic degreasing agent and 1 g / L of penetrant are added to the pretreatment working fluid for degreasing, the bath ratio is controlled at 1:10, and the solution is treated in an alternating cycle for 20 min under the conditions of 50°C and 0.07 MPa cyclic pressure difference.

[0045] Step S30 uses the degreased dyed yarn obtained in the previous step as the treatment object. Dyeing is carried out using a high-temperature and high-pressure yarn dyeing equipment and a disperse dye suitable for polyester covering layers. Before starting dyeing, dyeing water and disperse dye are added to the equipment, along with a dispersant and a leveling agent. The pH of the bath is adjusted to 4.5 to 5.5, and the preferred bath ratio is 1:8 to 1:15.

[0046] After installation, the dyeing process begins with phased temperature increases. The first phase increases the temperature at a rate of 0.7℃ / min to 0.9℃ / min, reaching 58℃ to 62℃; the second phase increases the temperature at a rate of 0.9℃ / min to 1.1℃ / min, reaching 88℃ to 92℃; and the third phase increases the temperature at a rate of 0.4℃ / min to 0.6℃ / min, reaching 128℃ to 132℃. The circulating pressure difference during the temperature increase phase is controlled at 0.10 MPa to 0.20 MPa, and the circulating pressure difference during the holding period at 128℃ to 132℃ for 20 to 60 minutes is controlled at 0.05 MPa to 0.10 MPa. The entire dyeing process employs an alternating circulation method. This phased temperature and pressure control ensures heat and dye transfer while mitigating the adverse effects of high-temperature liquid flow impact on the roll structure.

[0047] After reaching 128℃ to 132℃, the holding time is controlled according to the color depth. For dark color dyeing, the holding time is preferably 45 min to 60 min. After holding, the temperature is lowered to 58℃ to 62℃ at a rate of 1℃ / min to 1.5℃ / min, and the liquid is drained. Continuing the alternating cooling cycle helps to make the thermal history of the inner and outer layers of the cylinder more consistent and reduces structural recovery differences caused by excessively rapid cooling.

[0048] Step S40 can be continued in the same equipment. After the dyeing solution is drained, warm water and a reducing cleaning agent system are added to the equipment, the treatment temperature is raised to 80°C to 90°C, and reducing cleaning is performed for 18 to 22 minutes using an alternating circulation method under a circulating pressure difference of 0.07 MPa to 0.15 MPa. After the reducing cleaning is completed, the solution is rinsed with warm water, then a neutralizing solution is added to adjust the pH of the bath to 6.5 to 7.0, and the solution is drained from the tank.

[0049] In one specific embodiment, 2% OWF dispersible black was used in the dyeing working solution, along with 1 g / L dispersant and 1 g / L leveling agent, and the pH of the bath was adjusted to 5.0. Subsequently, the temperature was increased to 60°C at 0.8°C / min, to 90°C at 1°C / min, and to 130°C at 0.5°C / min. The circulating pressure difference was controlled at 0.15 MPa during the heating phase and at 0.07 MPa during the holding phase. After holding at 130°C for 60 min, the temperature was decreased to 60°C at 1°C / min and the solution was drained. Then, a reducing cleaning agent system containing 2 g / L sodium hydrosulfite and 1 g / L caustic soda was added, and the temperature was increased to 85°C. The solution was cleaned for 20 min in an alternating cyclic manner under a circulating pressure difference of 0.07 MPa, and the bath was neutralized to neutral using acetic acid.

[0050] Step S50 uses the dyed yarn package obtained and neutralized in the previous step as the processing target. The processed package is preferably placed in a hot air circulating drying device for tension-free hot air drying. Tension-free hot air drying means that no additional stretching tension is applied to the yarn body during the drying process, and static hot air drying or low torque support is preferred to avoid new stretching misalignment of the yarn during the drying process.

[0051] During drying, the hot air temperature is controlled at 60℃ to 70℃, and the distance between the rolls is controlled at 5 cm to 8 cm. By controlling the distance between the rolls, a relatively uniform hot air channel can be maintained between adjacent rolls, avoiding local heat accumulation or uneven heat dissipation. After drying, the rolls are balanced in a normal storage environment to further stabilize them before packaging.

[0052] The balancing process is preferably carried out for 20 to 26 hours. During the balancing process, no additional compression or stretching is applied to the roll, allowing the temperature and humidity state and the covering structure of the roll to gradually release and become consistent, thereby reducing the possibility of secondary exposure and increased burrs in the roll during subsequent unwinding, weaving, or packaging processes.

[0053] In one specific embodiment, the treated dyeing tubes are placed in a tension-free hot air environment and dried at 60°C, with the tube spacing controlled at 7 cm; after drying, they are equilibrated for 24 hours before being packaged or used subsequently.

[0054] The yarn processed through the above steps can be directly used as yarn for subsequent unwinding, weaving, or knitting. Because this invention controls the same technical problem in the package forming, dyeing, and post-dyeing drying stages, it can improve the surface integrity of the yarn and the stability of subsequent processing while ensuring basic dyeing completion.

[0055] For dyeing routes with different shades, the amount of disperse dye and the holding time at 130°C can be adjusted accordingly without departing from the technical concept of this invention. For dark routes, it is preferable to hold at 130°C for 45 to 60 minutes; for medium or light routes, the holding time can be appropriately shortened, but the staged heating, alternating cycle, and staged pressure difference control between the heating and holding stages should still be maintained.

[0056] In a preferred embodiment, the cyclic pressure difference during the heating stage is 0.15 MPa, and the cyclic pressure difference during the 130°C holding stage is 0.07 MPa. This combination of parameters ensures uniform liquid and heat distribution to both the inner and outer layers of the cylinder, while also reducing the continuous impact on the roll structure during the high-temperature holding stage.

[0057] The description of the above specification and embodiments is used to explain the technical solutions of the present invention, but does not constitute a limitation on the scope of protection of the present invention.

[0058] To further illustrate the beneficial effects of the dyeing and finishing method for polyester-coated basalt yarn disclosed in this invention, the following embodiments and comparative examples are provided in this specification.

[0059] The raw material used to implement this invention is polyester-coated basalt core yarn. The core yarn comprises a basalt core material and a polyester filament covering layer surrounding the basalt core material. The core yarn is preferably used for weaving or knitting functional shoe upper materials or clothing materials. Disperse dyes suitable for the polyester covering layer are used for dyeing. Pretreatment may employ nonionic degreasing agents and penetrants, and post-dyeing may employ a sodium hydrosulfite / caustic soda reducing cleaning system and an organic acid neutralizing agent.

[0060] The main equipment may include a conical winding machine, a high-temperature and high-pressure yarn dyeing machine, a hot air circulating drying device, and a static balancing frame, etc. All of the above equipment can be conventionally available in this field, and should be set and operated according to the process parameters given in this manual.

[0061] Example 1 Example 1 uses polyester-coated basalt yarn as raw material, and the finished product is black. First, a conical winding machine is used to wind the yarn into a double-tapered dyeing bobbin. The winding density is controlled at 0.30 g / cm³, the winding tension is controlled at 5 N / tex, and the package taper is controlled at 5° to obtain the package to be dyed.

[0062] The above-mentioned rolls were loaded into a high-temperature, high-pressure yarn dyeing machine for pre-treatment before degreasing. 2 g / L of nonionic degreasing agent and 1 g / L of penetrant were added to the treatment working solution, with a liquor ratio controlled at 1:10. The treatment was carried out at 50℃ and a circulating pressure difference of 0.07 MPa in an alternating cycle for 20 min, with the alternating cycle switching cycle controlled at 5 min / time.

[0063] After degreasing, drain the solution and add dyeing working solution to the equipment. The dyeing working solution uses 2% OWF dispersible black, with 1 g / L dispersant and 1 g / L leveling agent added, and the pH of the bath is adjusted to 5.0. Then, the temperature is increased to 60℃ at 0.8℃ / min, to 90℃ at 1℃ / min, and to 130℃ at 0.5℃ / min. The circulating pressure difference is controlled at 0.15 MPa during the heating stage and at 0.07 MPa during the holding stage. After holding at 130℃ for 60 min, the temperature is decreased to 60℃ at 1℃ / min and the solution is drained.

[0064] After dyeing, reduction cleaning and neutralization treatments were performed in the same equipment. A reduction cleaning agent system containing 2 g / L sodium hydrosulfite and 1 g / L caustic soda was added to the equipment, the temperature was raised to 85℃, and the treatment was carried out in an alternating cycle for 20 min under a circulating pressure difference of 0.07 MPa. After reduction cleaning, the solution was rinsed, and the pH of the bath was adjusted to neutral with acetic acid before being drained from the tank.

[0065] After dyeing, the yarn packages are dried using tension-free hot air drying. The drying temperature is controlled at 60℃, and the distance between the packages is controlled at 7 cm. No additional stretching tension is applied to the yarn package during the drying process. After drying, the packages are left to stand and equilibrate for 24 hours.

[0066] After balancing, the dyed and finished yarn sample of Example 1 was obtained.

[0067] Example 2 Example 2 uses the same type of polyester-coated basalt yarn as in Example 1 as the raw material. First, a conical winding machine is used to wind the yarn into a double-tapered dyeing bobbin, with the winding density controlled at 0.35 g / cm³, the winding tension controlled at 6.5 N / tex, and the package taper controlled at 6°.

[0068] The yarn rolls were loaded into a high-temperature, high-pressure package dyeing machine for pre-treatment before degreasing. 2 g / L of nonionic degreasing agent and 1 g / L of penetrant were added to the treatment working solution, with a liquor ratio controlled at 1:12. The treatment was carried out at 40℃ and a circulating pressure difference of 0.08 MPa for 25 minutes using an alternating circulation method. After degreasing, the solution was drained, and a dyeing working solution was added. The dyeing working solution contained 3% OWF dispersing black, 1.5 g / L of dispersant, and 1 g / L of leveling agent. The pH of the bath solution was adjusted to 4.8.

[0069] The temperature was then increased to 60℃ at 0.8℃ / min, to 90℃ at 1℃ / min, and to 130℃ at 0.5℃ / min. The differential pressure during the heating phase was controlled at 0.16 MPa, and the differential pressure during the holding phase was controlled at 0.08 MPa. After holding at 130℃ for 45 min, the temperature was decreased to 60℃ at 1.2℃ / min, and the liquid was drained. Subsequently, a reducing cleaning agent system containing 2 g / L sodium hydrosulfite and 1 g / L caustic soda was added under a cyclic pressure difference of 0.10 MPa at 85℃. This was repeated for 20 min using an alternating cyclic method, and the solution was neutralized to neutral using acetic acid.

[0070] The dyed yarns after treatment are dried with tension-free hot air. The drying temperature is controlled at 65℃, the yarn spacing is controlled at 6 cm, and a static hot air drying method is used during the drying process, without applying additional stretching tension to the yarn body.

[0071] After drying, the yarn was equilibrated for 24 hours to obtain the yarn sample after dyeing and finishing in Example 2.

[0072] Example 3 Example 3 uses the same type of polyester-coated basalt yarn as Example 1 as the raw material. First, a conical winding machine is used to wind the yarn into a double-tapered dyeing bobbin, with the winding density controlled at 0.40 g / cm³, the winding tension controlled at 8 N / tex, and the package taper controlled at 7°.

[0073] The yarn rolls are loaded into a high-temperature, high-pressure package dyeing machine for pre-treatment before degreasing. 1 g / L of nonionic degreasing agent and 0.5 g / L of penetrant are added to the treatment working solution, with a liquor ratio controlled at 1:15. The treatment is carried out at 30℃ and a circulating pressure difference of 0.05 MPa using an alternating circulation method for 30 min. After degreasing, the solution is drained, and dyeing working solution is added. The dyeing working solution uses 1% owf disperse dye, with 0.5 g / L of dispersant and 0.5 g / L of leveling agent added. The pH of the bath solution is adjusted to 5.5.

[0074] The temperature was then increased to 60℃ at 0.8℃ / min, to 90℃ at 1℃ / min, and to 130℃ at 0.5℃ / min. The differential pressure during the heating phase was controlled at 0.10 MPa, and the differential pressure during the holding phase was controlled at 0.05 MPa. After holding at 130℃ for 20 min, the temperature was decreased to 60℃ at 1.5℃ / min, and the liquid was drained. Subsequently, a reducing cleaning agent system containing 1 g / L sodium hydrosulfite and 1 g / L caustic soda was added under a cyclic pressure difference of 0.07 MPa at 80℃, and the mixture was treated in an alternating cycle for 20 min, followed by neutralization with an organic acid.

[0075] The dyed bobbins are then dried using tension-free hot air. The drying temperature is controlled at 70℃, the bobbin spacing is controlled at 5 cm, and a low-torque support method is used during the drying process to avoid applying additional stretching tension to the core yarn body.

[0076] After drying, the yarn was equilibrated for 24 hours to obtain the yarn sample after dyeing and finishing in Example 3.

[0077] Comparative Example 1 Comparative Example 1 uses the same raw materials and dyeing route as Example 1, but does not use the double-tapered low-density winding method of the present invention in the winding forming stage. Instead, it uses conventional high-density winding with a winding density controlled at 0.50 g / cm³. The remaining steps of degreasing, dyeing, reduction cleaning, neutralization, drying and balancing are all carried out according to the steps and parameters of Example 1.

[0078] Comparative Example 2 Comparative Example 2 used the same raw materials, roll packaging, and pretreatment route as Example 1. During dyeing, instead of the staged heating and pressure differential control of this invention, the temperature was directly increased to 130°C at the initial bath temperature at 1.5°C / min, with the pressure differential maintained at 0.15 MPa throughout the cycle. After holding at 130°C for 60 min, the temperature was decreased to 60°C at 1°C / min, and the liquid was drained. The remaining reduction cleaning, neutralization, drying, and equilibration steps were performed according to the steps and parameters of Example 1.

[0079] Comparative Example 3 Comparative Example 3 uses the same raw materials, roll packaging, degreasing and dyeing route as Example 1, but does not use an alternating circulation method in the degreasing, dyeing and reduction cleaning process, but always uses a unidirectional circulation method. The remaining steps and parameters are the same as in Example 1.

[0080] Comparative Example 4 Comparative Example 4 used the same raw materials, roll packaging, degreasing, dyeing, reduction cleaning and neutralization route as Example 1, but instead of using tensionless hot air drying and balancing after dyeing, the roll packaging was dried with ordinary forced hot air at 80°C, the distance between the rolls was controlled at 2 cm, and no 24-hour balancing was performed after drying. The other conditions were the same as in Example 1.

[0081] The samples prepared in the above embodiments and comparative examples were tested. All samples used polyester-covered basalt yarn from the same batch or within the same specification range, and were processed under the same equipment conditions according to their respective processes. At least three independently dyed bobbins were prepared as parallel samples for each group of samples, and samples were taken from the inner, middle, and outer layers of the bobbin during testing.

[0082] To ensure comparability among the various tests, all samples were placed in a standard environment with a temperature of 20℃ to 22℃ and a relative humidity of 65% to 70% for at least 24 hours before testing. For items requiring evaluation by trial weaving, all samples were prepared under the same weaving conditions and the same conditioning conditions.

[0083] The test items include the uniformity of dyeing of the inner and outer layers of the bobbin, the condition of exposed core material and burrs, and the itching sensation upon contact with the test sample.

[0084] The uniformity of dyeing between the inner and outer layers of the yarn package was evaluated using a standardized manual observation method. For each sample group, equal lengths of yarn were unwound from the inner, middle, and outer layers of the package, and the overall color consistency of each layer was compared under standard white light conditions. The evaluation results were categorized into five levels: uniform, fairly uniform, average, poor, and very poor.

[0085] The presence of exposed core material and burrs was evaluated using a standardized method combining manual observation and tactile confirmation. For each sample group, yarn of the same length was unwound from different layers. Under standard white light conditions, the surface of the yarn was observed for any protrusion, exposure, or localized burrs of the basalt core material. The presence of noticeable protrusions, sharp edges, or localized thorns was then confirmed by light touch with the fingers. Evaluation results were categorized into five levels: very little, few, moderate, many, and noticeable.

[0086] The itch sensation of the woven samples was evaluated using a standardized manual contact evaluation method. Small-scale fabric samples were prepared under identical weaving conditions for each group of samples, and after sample numbering, blind sample evaluations were conducted. Evaluators were preferably five or more adults with normal skin sensation, and the evaluation site was uniformly the inner forearm. Evaluation results were categorized into five levels: no obvious itch, slight itch, some itch, obvious itch, and severe itch.

[0087] The following results table uses manual evaluation to illustrate the relative differences between the examples and the comparative examples.

[0088] As can be seen from the results table, the core yarns prepared in Examples 1 to 3 are generally better than those in Comparative Examples 1 to 4 in terms of dyeing uniformity of the inner and outer layers of the bobbin. This indicates that after processing according to the process route of the present invention, the liquid and heat conditions of the inner and outer layers of the bobbin are more stable, and the dyeing consistency between different layers of the bobbin is better.

[0089]

[0090] Regarding the exposure of the core material and burrs, Examples 1 to 3 showed very little or no burrs, while Comparative Examples 1 to 4 showed moderate, significant, or obvious burrs. This indicates that the roll packing looseness control, staged temperature and pressure control, alternating cycles, and tension-free drying route adopted in this invention can effectively reduce the problems of basalt core material exposure and the resulting local burrs. Comparative Example 1 used higher density roll packing, Comparative Example 2 eliminated staged temperature rise and staged pressure difference, Comparative Example 3 eliminated alternating cycles, and Comparative Example 4 weakened post-dyeing tension-free stabilization control; all of these resulted in varying degrees of increased exposure and burrs, indicating that the above steps are interconnected in the entire process chain.

[0091] Regarding the itching sensation upon contact with the trial-woven samples, Examples 1 to 3 all showed slight itching, while Comparative Examples 1 and 2 showed some itching, and Comparative Examples 3 and 4 showed significant itching. This indicates that when the surface integrity of the yarn decreases and the core material is exposed and the burrs are aggravated, the subsequently woven samples are more likely to cause itching upon contact with the skin. Therefore, it can be seen that the present invention does not achieve improvement through a single process, but rather through a continuous combination of package forming, staged temperature dyeing, alternating cycles, reduction washing, tension-free drying, and balancing, thereby stabilizing the overall state of the yarn.

[0092] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.

[0093] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.

Claims

1. A dyeing and finishing method for polyester-coated basalt yarn, characterized in that, The polyester-coated basalt core yarn comprises an inner basalt core material and an outer polyester coating layer, and the dyeing and finishing method includes the following steps: S1. The polyester-coated basalt core yarn is wound into a double-tapered dyeing bobbin, and the winding density of the dyeing bobbin is 0.30-0.40 g / cm³. S2. The dyeing bobbin is loaded into a high-temperature and high-pressure yarn dyeing equipment and subjected to a pre-treatment for degreasing for 20-30 minutes under the conditions of 30-50℃ and 0.05-0.10 MPa circulating pressure difference. The pre-treatment for degreasing adopts an alternating circulation method of alternating circulation from inside to outside and from outside to inside of the dye liquor. S3. The dyeing cylinder after degreasing pretreatment is dyed with disperse dye. The dyeing includes a staged heating process: heating to 58-62℃ at 0.7-0.9℃ / min, heating to 88-92℃ at 0.9-1.1℃ / min, and heating to 128-132℃ at 0.4-0.6℃ / min. The circulating pressure difference during the staged heating process is 0.10-0.20 MPa, and the circulating pressure difference when holding at 128-132℃ for 20-60 min is 0.05-0.10 MPa. The entire dyeing process adopts the alternating circulation method. After staining, cool the solution to 58-62℃ at a rate of 1-1.5℃ / min and drain. S4. After the dyeing solution is drained, the dyeing tubes are subjected to reduction cleaning and neutralization treatment. The reduction cleaning is carried out for 18-22 minutes in an alternating circulation mode under the conditions of 80-90℃ and 0.07-0.15 MPa circulating pressure difference. S5. The dyeing tubes after reduction cleaning and neutralization treatment are dried with tensionless hot air at a temperature of 60-70℃ and a tube spacing of 5-8cm. After drying, the tubes are equilibrated for 20-26 hours.

2. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, In step S1, the winding tension is 5-8 N / tex and the roll taper is 5-7°.

3. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, In step S2, the pretreatment working solution for degreasing includes 1-3 g / L of nonionic degreasing agent and 0.5-1.5 g / L of penetrant, with a bath ratio of 1:8-1:

15.

4. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, The alternating circulation method described in steps S2 and S3 switches between outward circulation within the dye solution and inward circulation within the solution every 3-8 minutes.

5. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, In step S3, the amount of disperse dye used is 1-5% owf of the yarn mass, 0.5-2 g / L of dispersant and 0.5-1.5 g / L of leveling agent are added to the dyeing working solution, and the pH of the bath solution is adjusted to 4.5-5.

5.

6. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, In step S3, when performing dark staining, the incubation time at 128-132℃ is 45-60 min.

7. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, In step S4, the reducing cleaning agent system includes 1-3 g / L of sodium hydrosulfite and 1-2 g / L of caustic soda. The neutralization treatment uses organic acids to adjust the pH of the bath solution to 6.5-7.

0.

8. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, The tensionless hot air drying in step S5 means that no additional stretching tension is applied to the core yarn body during the drying process, and static hot air drying or low torque support is used.

9. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, In step S5, the balancing time is 20-26 hours.

10. The dyeing and finishing method for polyester-coated basalt yarn according to claim 1, characterized in that, The cyclic pressure difference during the heating stage in step S3 is 0.14-0.16 MPa, and the cyclic pressure difference during the heat preservation stage at 128-132℃ is 0.06-0.08 MPa.

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