Manufacturing device and manufacturing method of wool blended flame-retardant fabric

Abstract

The application provides a manufacturing device and manufacturing method of wool blended flame-retardant fabric, relates to the technical field of wool fabric processing, and comprises a pre-dissolution constant-temperature module, a pH-temperature linkage dye vat, a double-comb linkage unit and a central control system connected in sequence, wherein the central control system is electrically connected with the pre-dissolution constant-temperature module, the pH-temperature linkage dye vat and the double-comb linkage unit, is used for real-time monitoring of process parameters of each module and automatic adjustment; through the connection in sequence of the pre-dissolution constant-temperature module, the pH-temperature linkage dye vat and the double-comb linkage unit, and the intelligent regulation and control of the central control system, full-process automation of flame-retardant finishing is realized, manual material transfer and manual parameter adjustment are not needed, manual intervention is greatly reduced, production efficiency is improved, performance fluctuation between batches is avoided through accurate control of process parameters, and the flame-retardant performance of each batch of fabric is uniform and consistent, which is suitable for large-batch production requirements.

Description

Technical Field

[0001] This invention relates to the field of wool fabric processing technology, and in particular to a manufacturing apparatus and method for a wool blend flame-retardant fabric. Background Technology

[0002] Wool fabrics, due to their superior properties such as softness, comfort, warmth, breathability, and natural luster, are widely used in clothing, home textiles, and aerospace interiors. With the expansion of application scenarios, especially in special applications like aircraft seats, higher demands are being placed on the flame-retardant and hygiene safety performance of wool fabrics. Currently, flame-retardant finishing of wool fabrics mainly employs an intermittent processing mode. The core process includes flame retardant pre-dissolving, fabric flame-retardant treatment, dehydration and drying, and combing, and most processes use a separate "dyeing first, then flame retardant" process. For antibacterial requirements, post-treatment spraying of antibacterial agents is often used, with some solutions using blended antibacterial fibers, but this does not achieve a synergistic fit between flame-retardant and antibacterial functions. Furthermore, existing flame-retardant finishing equipment is mostly a decentralized structure, with each processing unit operating independently, requiring manual material transfer and parameter adjustment, relying on traditional feedback control methods to manage process parameters. Specifically, the traditional "step-by-step intermittent" processing mode has loose connections between units and requires a lot of manual intervention, which not only leads to low production efficiency but also easily causes fluctuations in process parameters between batches, resulting in uneven flame retardant performance of the fabric and making it unsuitable for mass production. The "dye first, then flame retardant" separate processing requires transferring the dyed wool fabric to different equipment multiple times for flame retardant finishing, which can easily cause damage to wool fibers, fabric pattern deformation, and color fading, making it difficult to achieve both flame retardant performance and appearance quality. Moreover, the antibacterial treatment and flame retardant treatment have poor synergy. Traditional spraying of antibacterial agents has the problem of easy loss of antibacterial components and short-lasting antibacterial effect. The solution of blending antibacterial fibers has not achieved chemical compatibility with the flame retardant system, which can easily lead to functional interference and cannot form a stable dual protection mechanism, making it difficult to meet the hygiene and safety requirements of special scenarios such as aircraft seats. In addition, the process parameter control precision is insufficient, and the adjustment of key parameters such as temperature and pH value is lagging, which further affects the overall performance of the fabric. Therefore, this invention proposes a manufacturing device and manufacturing method for wool blended flame retardant fabric to solve the problems existing in the prior art. Summary of the Invention

[0003] To address the aforementioned issues, this invention proposes a manufacturing apparatus and method for wool blend flame-retardant fabrics. Through the sequential linkage of a pre-melting constant temperature module, a pH-temperature linked dyeing vat, and a combing linkage unit, combined with the intelligent control of a central control system, the entire flame-retardant finishing process is automated. This eliminates the need for manual material transfer and parameter adjustment, significantly reducing human intervention. This not only improves production efficiency but also, through precise control of process parameters, prevents batch-to-batch performance fluctuations, ensuring uniform flame-retardant performance in each batch of fabric, thus meeting the needs of mass production.

[0004] To achieve the objectives of this invention, the following technical solution is provided: a manufacturing apparatus for wool blend flame-retardant fabric, comprising a pre-dissolving constant temperature module, a pH-temperature linked dyeing vat, a combing linkage unit, and a central control system, which are sequentially linked. The central control system is electrically connected to the pre-dissolving constant temperature module, the pH-temperature linked dyeing vat, and the combing linkage unit, respectively, and is used to monitor the process parameters of each module in real time and make automatic adjustments. The pre-dissolving constant temperature module is a sealed structure used for the pre-dissolving and constant temperature storage of the two-component flame retardant. The pH-temperature linkage dyeing vat integrates an online pH monitoring system, an automatic citric acid dripping system, and a temperature control system, and is suitable for dyeing-flame retardant co-bath treatment; the combing linkage unit integrates a non-contact airflow dehydration mechanism and a combing machine, realizing the integration of dehydration, washing, drying, and combing, and is suitable for the blending pretreatment of flame retardant tops and antibacterial woven fibers, forming a closed-loop continuous structure and realizing full-process automated connection.

[0005] Further improvements include: the pre-dissolving constant temperature module comprises a sealed reaction vessel, a heating mechanism, a temperature sensor, and a stirring mechanism. The temperature sensor collects the water temperature inside the reaction vessel in real time. The central control system dynamically adjusts the water temperature through the heating mechanism based on the detected water temperature value. Its temperature control employs a PID algorithm, with the specific formula as follows: ; Where u(t) is the output control quantity of the heating mechanism, in W; Kp is the proportional coefficient, ranging from 1.2 to 1.8; e(t) is the deviation between the detected water temperature at time t and the preset target value, in °C; Ti is the integral time constant, in s, ranging from 30 to 60 s; and Td is the differential time constant, in s, ranging from 5 to 15 s. For integration variables, The value is the rate of change of water temperature deviation at time t, in °C / s.

[0006] Further improvements include: a liquor ratio adjustment mechanism is installed inside the pH-temperature linked dyeing vat; the central control system precisely controls the liquor ratio to 1:10 through this mechanism; the online pH monitoring system collects the pH value of the bath solution in real time; and the automatic citric acid addition system automatically adds citric acid based on the pH detection value. The pH adjustment uses a proportional adjustment algorithm, with the specific formula as follows: ; Where V(t) is the dropping rate of citric acid at time t, in mL / min; Kv is the proportional adjustment coefficient, ranging from 0.8 to 1.2; pHset is the preset pH target value, from 2.0 to 2.5; and pHdet(t) is the pH value of the bath solution at time t.

[0007] Further improvements are made in the following aspects: the non-contact airflow dehydration mechanism of the combing linkage unit adopts a high-pressure airflow jet method, with the airflow pressure controlled at 0.3~0.5MPa, and the moisture content of the wool top after dehydration is ≤15%; the combing speed of the combing machine is 20~30m / min, and the combing spacing is 0.5~1.0mm, ensuring that the wool fibers are not damaged.

[0008] Further improvements are made in the following aspects: the preset water temperature of the pre-dissolving constant temperature module is 65~75℃, the two-component flame retardant is HYYS-Shield FR410 A / B, and its pre-dissolving mass ratio is 1:1; the preset temperature of the pH-temperature linkage dyeing tank is 80±1℃, the constant temperature holding time is 1 hour, and the pH value is controlled at 2.0~2.5.

[0009] A method for manufacturing a wool blend flame-retardant fabric includes the following steps: S1: Flame retardant pre-dissolution. Add the two-component flame retardant HYYS-Shield FR410 A / B in a 1:1 ratio to the sealed reactor of the pre-dissolution constant temperature module, add deionized water, start the stirring mechanism, and dynamically maintain the water temperature at 65~75℃ through the heating mechanism and temperature sensor for 30~40 minutes to obtain a uniform flame retardant pre-solution. S2: Dyeing-Flame Retardant Co-bath Treatment. The dyed wool tops are sent into a pH-temperature linked dyeing vat, and the flame retardant pre-solution prepared in S1 is added. The liquor ratio is controlled to 1:10 by the liquor ratio adjustment mechanism. The pH online monitoring system and the citric acid automatic dripping system are started to control the pH value of the bath solution at 2.0~2.5. At the same time, the temperature control system is started to raise the temperature in the dyeing vat to 80±1℃ and keep it at a constant temperature for 1 hour to complete the simultaneous dyeing and flame retardant treatment. S3: Dehydration and combing. The wool tops treated with flame retardant in S2 are sent to the combing linkage unit and dehydrated by a non-contact airflow dehydration mechanism. After dehydration, the moisture content of the wool tops is ≤15%. Then, they are directly sent to the combing machine to complete the washing, drying and combing processes in sequence, resulting in clean, dry and evenly combed flame retardant wool tops. S4: Flame-retardant and antibacterial blended fabric. The flame-retardant wool tops obtained in S3 are blended with the accompanying fibers that have undergone permanent antibacterial treatment in a preset ratio, and then processed through drawing, roving, and spinning processes to obtain a wool blended flame-retardant and antibacterial fabric. S5: Finished product inspection. The fabric prepared in S4 is tested for flame retardancy, antibacterial properties, and appearance quality. Once the test is passed, it is considered a finished product.

[0010] A further improvement is made in S4, where the accompanying fiber is either a bio-based permanent antibacterial fiber or a metal-based permanent antibacterial fiber, and the metal-based permanent antibacterial fiber is a fiber loaded with silver ions, copper ions, or zinc ions; the blending ratio of the flame-retardant sliver and the antibacterial accompanying fiber is determined by an optimization algorithm, specifically using the following formula: ; in, The blending ratio of flame-retardant wool tops is %, with a value range of 70%~90%; FRreq is the preset flame-retardant performance index of the fabric, limiting oxygen index (LOI), with a value range of ≥32%; FRb is the flame-retardant performance index of the antibacterial accompanying fibers, limiting oxygen index (LOI), with a value range of 18%~22%; FRf is the flame-retardant performance index of the flame-retardant wool tops, limiting oxygen index (LOI), with a value range of ≥38%; the blending ratio of antibacterial accompanying fibers is... The value ranges from 10% to 30%.

[0011] Further improvements are made in that: the bio-based permanent antibacterial fiber is prepared by chemically bonding natural antibacterial active substances with the fiber matrix, and the metal-based permanent antibacterial fiber is prepared by introducing antibacterial metal ions into the fiber surface and interior through ion exchange or covalent grafting. The antibacterial effect of both types of antibacterial fibers can withstand more than 50 standard washes without degradation.

[0012] Further improvements are made in the following aspects: In S4, the drawing process adopts a two-stage blending process, with the machine speed controlled at 300~400m / min and the basis weight controlled at 4~6g / m; the draft ratio of the roving process is 5~8 times, and the draft ratio of the spinning process is 15~20 times, to ensure the uniform distribution of fibers in the blended fabric.

[0013] Further improvements are made in the following aspects: In S5, the flame retardant performance test specifically includes: limiting oxygen index (LOI) ≥ 32%, no dripping, and no smoldering; the antibacterial performance test specifically includes: inhibition rate of ≥ 90% against Escherichia coli and Staphylococcus aureus; the appearance quality test includes color fastness test, with color fastness to soap washing and color fastness to rubbing both ≥ 4 grades, no pattern deformation, and no fiber damage.

[0014] The beneficial effects of this invention are as follows: 1. This invention achieves fully automated flame-retardant finishing by sequentially linking the pre-dissolving constant temperature module, pH-temperature linked dyeing vat, and recombing linkage unit, combined with the intelligent control of the central control system. This eliminates the need for manual material transfer and parameter adjustment, significantly reducing human intervention. This not only improves production efficiency but also eliminates batch-to-batch performance fluctuations through precise control of process parameters, ensuring uniform flame-retardant performance of each batch of fabric, thus meeting the needs of mass production. At the same time, the integrated design of non-contact airflow dehydration and recombing avoids fiber damage and contamination, preserving the original characteristics of wool fibers.

[0015] 2. This invention performs flame-retardant finishing directly on dyed wool tops in the same dyeing vat, integrating pH adjustment, temperature control, and fabric support functions. It precisely controls key process parameters such as liquor ratio, temperature, and pH value, avoiding the problems of wool fabric pattern deformation and color fading caused by multiple transfer treatments. While ensuring that the flame-retardant performance meets the standards, it effectively preserves the original appearance quality of the fabric, simplifies the production process, further improves production efficiency, and reduces production costs. At the same time, through precise control of process parameters, it improves the dyeing uniformity and color fastness of the fabric, meeting the appearance requirements of high-end fabrics.

[0016] 3. This invention addresses the hygiene and safety requirements of special scenarios such as aircraft seats. By combining flame-retardant treatment of wool tops with antibacterial blended fibers, it achieves dual protection of flame retardancy and antibacterial functions. The two functional components are chemically compatible and functionally complementary, forming a stable protective mechanism of "overall fabric flame retardancy + surface area antibacterial". The antibacterial blended fibers are prepared using a permanent antibacterial process, ensuring that the antibacterial effect can withstand more than 50 standard washes without degradation. At the same time, it helps to improve the wool fabric's resistance to microbial decomposition, inhibiting the odor and strength reduction caused by microbial growth under humid or long-term storage conditions, comprehensively improving the hygiene and safety performance and service life of the fabric, and adapting to the needs of high-end special scenarios. Attached Figure Description

[0017] Figure 1 This is a diagram showing the device composition of the present invention; Figure 2 This is a flowchart of the method of the present invention. Detailed Implementation

[0018] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention. Example 1

[0019] according to Figure 1 , 2As shown in the figure, this embodiment proposes a manufacturing apparatus and method for a wool blend flame-retardant fabric. It uses 20-count high-quality wool tops (fiber length 32~35mm, fineness 20.5μm, impurity content ≤0.3%), and the antibacterial accompanying fiber is a silver ion metal-based permanent antibacterial fiber (antibacterial metal ion loading 0.3~0.5wt%). The specific steps are as follows: S1: Flame retardant pre-dissolution. Take 500g each of the two-component flame retardant HYYS-Shield FR410 A agent and B agent, and add them to a 10L sealed reactor of the pre-dissolution constant temperature module at a 1:1 (mass ratio). Add 8L of deionized water, start the stirring mechanism (stirring speed 300r / min), and dynamically maintain the water temperature at 70±0.5℃ through the PID temperature control algorithm (Kp=1.5, Ti=45s, Td=10s). Continue pre-dissolution for 35min. During this period, take a sample every 10min to check the dissolution status of the flame retardant. After the pre-dissolution is completed, a uniform flame retardant pre-solution with a concentration of 100g / L is obtained. There is no flame retardant precipitation or sedimentation, and the light transmittance is ≥98%.

[0020] S2: Dyeing-Flame Retardant Co-treatment. Take 10kg of dyed wool tops (dyeing color code: navy blue, color fastness pre-test ≥4 grade) and put them into a pH-temperature linkage dyeing tank with an effective volume of 100L. Add 8L of the flame retardant pre-solution prepared in S1. The bath ratio is precisely controlled to 1:10 through the bath ratio adjustment mechanism. Start the pH online monitoring system (detection accuracy ±0.05) and the citric acid automatic dripping system. The pH value of the bath solution is stably controlled at 2.2±0.1 through the pH ratio adjustment algorithm (Kv=1.0). At the same time, start the temperature control system and raise the temperature in the dyeing tank to 80℃ at a heating rate of 2℃ / min. Maintain the temperature for 1 hour. During the heat preservation period, stir for 5 minutes every 15 minutes (stirring speed 150r / min). The dyeing and flame retardant treatment is completed simultaneously. Take out the wool tops for observation. There is no fading or deformation, and the color of the wool tops is uniform.

[0021] S3: Dehydration and Combing. The flame-retardant treated wool tops are fed into the combing unit. The non-contact airflow dehydration mechanism uses a ring-shaped high-pressure airflow jet method. The airflow pressure is stably controlled at 0.4MPa, the airflow temperature is 45℃, and the dehydration time is 10min. After dehydration, the moisture content of the wool tops is measured to be 12±0.5%. Then, it directly enters the combing machine. The combing speed is adjusted to 25m / min, the combing spacing is 0.8mm, and the comb needle density is 300 needles / 10cm. The process of washing (rinsing with deionized water at 40℃), drying (drying temperature at 60℃, drying time at 20min) and combing is completed in sequence to obtain clean, dry, and uniformly combed flame-retardant wool tops. The fiber damage rate is measured to be 0.5%, with no tangling or broken fibers.

[0022] S4: Flame-retardant and antibacterial blend. Based on the blend ratio optimization algorithm, the preset limiting oxygen index (LOI) of the fabric is 34% (FRreq=34%). The LOI of the antibacterial accompanying fiber (silver ion metal base) is known to be 20% (FRb=20%), and the LOI of the flame-retardant wool top is 38% (FRf=38%). The blend ratio of the flame-retardant wool top is then calculated. =(34-20) / (38-20)×100%=77.8%, take 78%, the proportion of antibacterial woven fiber blend is 22%; take 7.8kg of flame-retardant wool top and 2.2kg of antibacterial woven fiber, and feed it into the drawing frame using a two-stage blending process. The first drawing speed is 320m / min, and the basis weight is 5.5g / m. The second drawing speed is 350m / min, and the basis weight is 5g / m. Then it enters the roving frame with a draft ratio of 6 times and a roving basis weight of 8g / 10m. Finally, it enters the spinning frame with a draft ratio of 18 times and a spinning specification of 40 count, resulting in a wool blend flame-retardant and antibacterial fabric with a fabric weight of 250g / m. 2 Thickness 0.8mm.

[0023] S5: Finished product inspection. The prepared fabrics are comprehensively tested according to the corresponding standards: Flame retardant performance is performed according to FZ / T73074-2023 standard, limiting oxygen index (LOI) = 34.5%, vertical burning test shows no dripping or smoldering, and burning time ≤ 3s; Antibacterial performance is performed according to GB / T 21295—2024 standard, with inhibition rates of 92% and 93% against Escherichia coli (ATCC 25922) and Staphylococcus aureus (ATCC 6538) respectively, and the inhibition rates remain at 89% and 90% after 50 washes; In appearance quality inspection, color fastness to soap washing (40℃, 30min) is grade 4.5, color fastness to rubbing (dry rubbing / wet rubbing) is grade 4 / 3.5, there is no pattern deformation, no fiber damage, no obvious pilling, and all indicators meet the usage requirements of aviation seat fabrics. Example 2

[0024] according to Figure 1 , 2 As shown in the figure, this embodiment proposes a manufacturing apparatus and method for a wool blend flame-retardant fabric. It uses 25-count high-quality wool tops (fiber length 30-33mm, fineness 18.8μm, impurity content ≤0.3%), and the antibacterial accompanying fiber is a bio-based permanent antibacterial fiber (the natural antibacterial active substance is tea saponin, with a loading of 1.2-1.5wt%). The specific steps are as follows: S1: Flame retardant pre-dissolution. Take 400g each of the two-component flame retardant HYYS-Shield FR410 A and B components and add them to the 8L sealed reactor of the pre-dissolution constant temperature module at a 1:1 (mass ratio). Add 6.4L of deionized water and start the stirring mechanism (stirring speed 280r / min). The water temperature is dynamically maintained at 65±0.5℃ using a PID temperature control algorithm (Kp=1.2, Ti=30s, Td=5s). Continue pre-dissolution for 40min. During this period, take a sample every 10min to check the dissolution status of the flame retardant. After the pre-dissolution is completed, a uniform flame retardant pre-solution with a concentration of 100g / L is obtained. There is no flame retardant precipitation or sedimentation, and the light transmittance is ≥97%.

[0025] S2: Dyeing-Flame Retardant Co-bath Treatment. Take 8 kg of dyed wool tops (dyeing color code: light gray, color fastness pre-test ≥ 4 grade) and put them into a pH-temperature linkage dyeing tank with an effective volume of 80L. Add 6.4L of the flame retardant pre-solution prepared in S1. The liquor ratio is precisely controlled to 1:10 through the liquor ratio adjustment mechanism. Start the pH online monitoring system (detection accuracy ±0.05) and the citric acid automatic dripping system. The pH value of the bath solution is stably controlled at 2.0±0.1 through the pH ratio adjustment algorithm (Kv=0.8). At the same time, start the temperature control system and raise the temperature in the dyeing tank to 79℃ at a heating rate of 1.5℃ / min. Maintain the temperature for 1 hour. During the heat preservation period, stir for 5 minutes every 15 minutes (stirring speed 120r / min). The dyeing and flame retardant treatment is completed simultaneously. Take out the wool tops for observation. There is no fading or deformation, and the color of the wool tops is uniform.

[0026] S3: Dehydration and Combing. The flame-retardant treated wool tops are fed into the combing unit. The non-contact airflow dehydration mechanism uses a ring-shaped high-pressure airflow jet method. The airflow pressure is stably controlled at 0.3MPa, the airflow temperature is 40℃, and the dehydration time is 12min. After dehydration, the moisture content of the wool tops is measured to be 14±0.5%. Then, it directly enters the combing machine. The combing speed is adjusted to 20m / min, the combing spacing is 0.5mm, and the comb needle density is 320 needles / 10cm. The process of washing (rinsing with deionized water at 38℃), drying (drying temperature 58℃, drying time 25min) and combing is completed in sequence to obtain clean, dry, and uniformly combed flame-retardant wool tops. The fiber damage rate is measured to be 0.6%, with no tangling or broken fibers.

[0027] S4: Flame-retardant and antibacterial blend. Based on the blend ratio optimization algorithm, the preset limiting oxygen index (LOI) of the fabric is 32% (FRreq=32%). The known LOI of the antibacterial accompanying fiber (bio-based) is 18% (FRb=18%), and the LOI of the flame-retardant wool top is 38% (FRf=38%). The blend ratio of the flame-retardant wool top is then calculated. =(32-18) / (38-18)×100%=70%, the blending ratio of antibacterial woven fibers is 30%; take 7kg of flame-retardant wool tops and mix them with 3kg of antibacterial woven fibers, and feed them into the drawing frame using a two-stage blending process. The first drawing speed is 280m / min, and the basis weight is 4.5g / m. The second drawing speed is 300m / min, and the basis weight is 4g / m. Then it enters the roving frame with a draft ratio of 5 times and a roving basis weight of 7g / 10m. Finally, it enters the spinning frame with a draft ratio of 15 times and a spinning specification of 45 count, resulting in a wool blend flame-retardant and antibacterial fabric with a fabric weight of 220g / m² and a thickness of 0.7mm.

[0028] S5: Finished product inspection. The prepared fabrics are comprehensively tested according to the corresponding standards: Flame retardant performance is performed according to FZ / T73074-2023 standard, limiting oxygen index LOI=32.2%, vertical burning test shows no dripping or smoldering, and burning time ≤4s; Antibacterial performance is performed according to GB / T 21295—2024 standard, with inhibition rates of 90% and 91% against Escherichia coli (ATCC 25922) and Staphylococcus aureus (ATCC 6538) respectively, and the inhibition rates remain at 88% and 89% after 50 washes; In appearance quality inspection, color fastness to soap washing (40℃, 30min) is grade 4, color fastness to rubbing (dry rubbing / wet rubbing) is grade 4 / 3.5, with no pattern deformation, no fiber damage, and no obvious pilling, and all indicators meet the requirements for high-end home textile fabrics. Example 3

[0029] according to Figure 1 , 2 As shown in the figure, this embodiment proposes a manufacturing apparatus and method for a wool blend flame-retardant fabric. It uses 18-count high-quality wool tops (fiber length 35~38mm, fineness 22.3μm, impurity content ≤0.3%), and the antibacterial accompanying fiber is a copper ion metal-based permanent antibacterial fiber (antibacterial metal ion loading 0.4~0.6wt%). The specific steps are as follows: S1: Flame retardant pre-dissolution. Take 600g each of the two-component flame retardant HYYS-Shield FR410 A and B components and add them to a 12L sealed reactor of the pre-dissolution constant temperature module at a 1:1 (mass ratio). Add 9.6L of deionized water and start the stirring mechanism (stirring speed 320r / min). The water temperature is dynamically maintained at 75±0.5℃ using a PID temperature control algorithm (Kp=1.8, Ti=60s, Td=15s). Continue pre-dissolution for 30min. During this period, take a sample every 10min to check the dissolution status of the flame retardant. After the pre-dissolution is completed, a uniform flame retardant pre-solution with a concentration of 100g / L is obtained. There is no flame retardant precipitation or sedimentation, and the light transmittance is ≥99%.

[0030] S2: Dyeing-Flame Retardant Co-bath Treatment. Take 12kg of dyed wool tops (dyeing color code: off-white, color fastness pre-test ≥4 grade) and put them into a pH-temperature linkage dyeing tank with an effective volume of 120L. Add 9.6L of the flame retardant pre-solution prepared in S1. The bath ratio is precisely controlled to 1:10 through the bath ratio adjustment mechanism. Start the pH online monitoring system (detection accuracy ±0.05) and the citric acid automatic dripping system. The pH value of the bath solution is stably controlled at 2.5±0.1 through the pH ratio adjustment algorithm (Kv=1.2). At the same time, start the temperature control system and raise the temperature in the dyeing tank to 81℃ at a heating rate of 2.5℃ / min. Maintain the temperature for 1 hour. During the heat preservation period, stir for 5 minutes every 15 minutes (stirring speed 180r / min). The dyeing and flame retardant treatment is completed simultaneously. Take out the wool tops for observation. There is no fading or deformation, and the color of the wool tops is uniform.

[0031] S3: Dehydration and Combing. The flame-retardant treated wool tops are fed into the combing unit. The non-contact airflow dehydration mechanism uses a ring-shaped high-pressure airflow jet method. The airflow pressure is stably controlled at 0.5MPa, the airflow temperature is 50℃, and the dehydration time is 8min. After dehydration, the moisture content of the wool tops is tested and found to be 10±0.5%. Then, it directly enters the combing machine. The combing speed is adjusted to 30m / min, the combing spacing is 1.0mm, and the comb needle density is 280 needles / 10cm. The process of washing (rinsing with deionized water at 42℃), drying (drying temperature at 62℃, drying time at 18min) and combing is completed in sequence to obtain clean, dry, and uniformly combed flame-retardant wool tops. The fiber damage rate is tested to be 0.4%, with no tangling or broken fibers.

[0032] S4: Flame-retardant and antibacterial blend. Based on the blend ratio optimization algorithm, the preset limiting oxygen index (LOI) of the fabric is 36% (FRreq=36%). The known LOI of the antibacterial accompanying fiber (copper ion metal matrix) is 22% (FRb=22%), and the LOI of the flame-retardant wool top is 38% (FRf=38%). The blend ratio of the flame-retardant wool top is then calculated. =(36-22) / (38-22)×100%=87.5%, take 88%, the proportion of antibacterial woven fiber blend is 12%; take 8.8kg flame-retardant wool top and 1.2kg antibacterial woven fiber and mix them. Feed them into the drawing frame and use a two-stage blending process. The first drawing speed is 380m / min and the basis weight is 6.5g / m. The second drawing speed is 400m / min and the basis weight is 6g / m. Then it enters the roving frame with a draft ratio of 8 times and a roving basis weight of 9g / 10m. Finally, it enters the spinning frame with a draft ratio of 20 times and a spinning specification of 35 count. The result is a wool blend flame-retardant and antibacterial fabric with a fabric weight of 280g / m² and a thickness of 0.9mm.

[0033] S5: Finished product inspection. The prepared fabrics are comprehensively tested according to the corresponding standards: Flame retardant performance is performed according to FZ / T73074-2023 standard, limiting oxygen index (LOI) = 36.3%, vertical burning test shows no dripping or smoldering, and burning time ≤ 2s; Antibacterial performance is performed according to GB / T 21295—2024 standard, with inhibition rates of 94% and 95% against Escherichia coli (ATCC 25922) and Staphylococcus aureus (ATCC 6538) respectively, and the inhibition rates remain at 92% and 93% after 50 washes; In appearance quality inspection, color fastness to soap washing (40℃, 30min) is grade 4.5, color fastness to rubbing (dry rubbing / wet rubbing) is grade 4.5 / 4, with no pattern deformation, no fiber damage, and no obvious pilling. All indicators meet the stringent requirements for high-end aviation seat fabrics. Comparative Example

[0034] The specific steps using traditional manufacturing methods are as follows: S1: Flame retardant pre-dissolution. The two-component flame retardant HYYS-Shield FR410 A / B is dissolved in an open container at a ratio of 1:1 (by mass). The water is allowed to cool naturally without temperature control, and some of the flame retardant is released.

[0035] S2: Dyeing treatment. The wool tops are fed into the dyeing machine. After dyeing, they are manually transferred to the flame retardant treatment tank, where flame retardant solution is added. The pH value is manually adjusted to 2.2, and the temperature is manually controlled at 75~85℃. The temperature is maintained for 1 hour, and the wool tops are stirred manually during the process. The wool tops may fade or deform slightly.

[0036] S3: Dehydration and combing. The flame-retardant treated wool tops are manually transferred to the dehydrator and dehydrated by extrusion. After dehydration, the moisture content of the wool tops is 20%. They are then manually transferred to the combing machine to complete the combing process, during which some fibers are damaged.

[0037] S4: Blending treatment, which involves blending flame-retardant wool tops with ordinary spun fibers that have not undergone permanent antibacterial treatment at a ratio of 78:22, and then using traditional spinning processes to obtain wool blended fabric.

[0038] S5: Finished product inspection. The test results showed that the limiting oxygen index (LOI) of the fabric was 28%, which did not meet the flame retardant requirements; the antibacterial rates against Escherichia coli and Staphylococcus aureus were 65% and 68%, respectively, indicating poor antibacterial effect; the color fastness to washing was grade 3, and the color fastness to rubbing was grade 3, with slight pattern deformation and fiber damage; the production efficiency was 42% lower than that of Example 1, and the batch-to-batch LOI deviation was 3.5%.

[0039] Validation data The product performance and production efficiency of the examples and comparative examples were comprehensively tested according to the following standards: flame retardancy was tested according to FZ / T 73074-2023, antibacterial performance was tested according to GB / T 21295-2024, color fastness was tested according to GB / T 3921-2008, production efficiency was measured by the length of fabric produced per unit time, and batch-to-batch performance fluctuations were measured by the deviation of limiting oxygen index (LOI). Specific data are shown in the table below. As can be seen from the above data, the wool blend flame-retardant fabric prepared in the embodiments of the present invention meets the standard requirements in terms of flame retardant performance, antibacterial performance, and appearance quality. The production efficiency is more than 40% higher than that of the comparative example, the performance fluctuation between batches is small, the antibacterial effect can withstand more than 50 standard washes without decay, and the fiber damage rate is low. In contrast, the fabric prepared by the comparative example using the traditional method does not meet the standard requirements in any of its properties, has low production efficiency, and large fluctuations between batches.

[0040] This invention achieves fully automated flame-retardant finishing through the sequential linkage of a pre-dissolving constant-temperature module, a pH-temperature linked dyeing vat, and a combing linkage unit, combined with intelligent control of a central control system. This eliminates the need for manual material transfer and parameter adjustment, significantly reducing human intervention and improving production efficiency. Furthermore, precise control of process parameters prevents batch-to-batch performance fluctuations, ensuring uniform flame-retardant performance in each batch of fabric, thus meeting the demands of mass production. Simultaneously, the integrated design of non-contact airflow dehydration and combing avoids fiber damage and contamination, preserving the original characteristics of the wool fibers. This invention performs flame-retardant finishing directly on dyed wool tops within the same dyeing vat, integrating pH adjustment, temperature control, and fabric support functions. Precise control of key process parameters such as liquor ratio, temperature, and pH value avoids the problems of pattern deformation and color fading in wool fabrics caused by multiple transfer processes. While ensuring flame-retardant performance meets standards, it effectively preserves the original appearance quality of the fabric, simplifies the production process, further improves production efficiency, and reduces production costs. At the same time, precise control of process parameters improves the uniformity of dyeing and color fastness, meeting the appearance requirements of high-end fabrics. This invention addresses the hygiene and safety requirements of special scenarios such as aircraft seats. It achieves dual protection of flame retardancy and antibacterial functions through a synergistic blending of flame-retardant treatment of wool tops and antibacterial fibers. The two functional components are chemically compatible and functionally complementary, forming a stable protective mechanism of "overall fabric flame retardancy + surface antibacterial." The antibacterial fibers are prepared using a permanent antibacterial process, ensuring that the antibacterial effect can withstand more than 50 standard washes without degradation. At the same time, it helps improve the wool fabric's resistance to microbial decomposition, inhibiting the growth of microorganisms that cause odor and strength loss under humid or long-term storage conditions. This comprehensively improves the hygiene and safety performance and service life of the fabric, making it suitable for high-end special scenario needs.

[0041] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing apparatus for a wool blend flame-retardant fabric, comprising a pre-melting constant temperature module, a pH-temperature linked dyeing vat, a combing linkage unit, and a central control system, wherein the apparatus is sequentially linked, characterized in that: The central control system is electrically connected to the pre-dissolving constant temperature module, the pH-temperature linkage dyeing vat, and the combing linkage unit, respectively, and is used to monitor the process parameters of each module in real time and make automatic adjustments; the pre-dissolving constant temperature module is a closed structure and is used for the pre-dissolving and constant temperature storage of the two-component flame retardant. The pH-temperature linkage dyeing vat integrates an online pH monitoring system, an automatic citric acid dripping system, and a temperature control system, and is suitable for dyeing-flame retardant co-bath treatment; the combing linkage unit integrates a non-contact airflow dehydration mechanism and a combing machine, realizing the integration of dehydration, washing, drying, and combing, and is suitable for the blending pretreatment of flame retardant tops and antibacterial woven fibers, forming a closed-loop continuous structure and realizing full-process automated connection.

2. The apparatus for manufacturing a wool blend flame-retardant fabric according to claim 1, characterized in that: The pre-dissolving constant temperature module includes a sealed reaction vessel, a heating mechanism, a temperature sensor, and a stirring mechanism. The temperature sensor collects the water temperature inside the reaction vessel in real time. The central control system dynamically adjusts the water temperature through the heating mechanism based on the detected water temperature value. Its temperature control employs a PID algorithm, with the specific formula as follows: ; Where u(t) is the output control quantity of the heating mechanism, in W; Kp is the proportional coefficient, ranging from 1.2 to 1.8; e(t) is the deviation between the detected water temperature at time t and the preset target value, in °C; Ti is the integral time constant, in s, ranging from 30 to 60 s; and Td is the differential time constant, in s, ranging from 5 to 15 s. For integration variables, The value is the rate of change of water temperature deviation at time t, in °C / s.

3. The apparatus for manufacturing a wool blend flame-retardant fabric according to claim 1, characterized in that: The pH-temperature linked dyeing vat is equipped with a liquor ratio adjustment mechanism. The central control system precisely controls the liquor ratio to 1:10 through this mechanism. The online pH monitoring system collects the pH value of the bath solution in real time. The automatic citric acid addition system automatically adds citric acid based on the pH detection value. The pH adjustment uses a proportional adjustment algorithm, and the specific formula is as follows: Where V(t) is the dropping rate of citric acid at time t, in mL / min; Kv is the proportional adjustment coefficient, ranging from 0.8 to 1.2; pHset is the preset pH target value, from 2.0 to 2.5; and pHdet(t) is the pH value of the bath solution at time t.

4. The apparatus for manufacturing a wool blend flame-retardant fabric according to claim 1, characterized in that: The non-contact airflow dehydration mechanism of the combing linkage unit adopts a high-pressure airflow jet method, with the airflow pressure controlled at 0.3~0.5MPa, and the moisture content of the wool top after dehydration is ≤15%; the combing speed of the combing machine is 20~30m / min, and the combing spacing is 0.5~1.0mm, ensuring that the wool fibers are not damaged.

5. The apparatus for manufacturing a wool blend flame-retardant fabric according to claim 1, characterized in that: The preset water temperature of the pre-dissolving constant temperature module is 65~75℃, and the two-component flame retardant is HYYS-Shield FR410 A / B with a pre-dissolving mass ratio of 1:

1. The preset temperature of the pH-temperature linkage dyeing tank is 80±1℃, the constant temperature holding time is 1 hour, and the pH value is controlled at 2.0~2.

5.

6. A method for manufacturing a wool blend flame-retardant fabric, using the apparatus for manufacturing a wool blend flame-retardant fabric as described in any one of claims 1-5, characterized in that: Includes the following steps: S1: Flame retardant pre-dissolution. Add the two-component flame retardant HYYS-Shield FR410 A / B in a 1:1 ratio to the sealed reactor of the pre-dissolution constant temperature module, add deionized water, start the stirring mechanism, and dynamically maintain the water temperature at 65~75℃ through the heating mechanism and temperature sensor for 30~40 minutes to obtain a uniform flame retardant pre-solution. S2: Dyeing-Flame Retardant Co-bath Treatment. The dyed wool tops are sent into a pH-temperature linked dyeing vat, and the flame retardant pre-solution prepared in S1 is added. The liquor ratio is controlled to 1:10 by the liquor ratio adjustment mechanism. The pH online monitoring system and the citric acid automatic dripping system are started to control the pH value of the bath solution at 2.0~2.

5. At the same time, the temperature control system is started to raise the temperature in the dyeing vat to 80±1℃ and keep it at a constant temperature for 1 hour to complete the simultaneous dyeing and flame retardant treatment. S3: Dehydration and combing. The wool tops treated with flame retardant in S2 are sent to the combing linkage unit and dehydrated by a non-contact airflow dehydration mechanism. After dehydration, the moisture content of the wool tops is ≤15%. Then, they are directly sent to the combing machine to complete the washing, drying and combing processes in sequence, resulting in clean, dry and evenly combed flame retardant wool tops. S4: Flame-retardant and antibacterial blended fabric. The flame-retardant wool tops obtained in S3 are blended with the accompanying fibers that have undergone permanent antibacterial treatment in a preset ratio, and then processed through drawing, roving, and spinning processes to obtain a wool blended flame-retardant and antibacterial fabric. S5: Finished product inspection. The fabric prepared in S4 is tested for flame retardancy, antibacterial properties, and appearance quality. Once the test is passed, it is considered a finished product.

7. The method for manufacturing a wool blend flame-retardant fabric according to claim 6, characterized in that: In step S4, the accompanying fiber is either a bio-based permanent antibacterial fiber or a metal-based permanent antibacterial fiber, wherein the metal-based permanent antibacterial fiber is a fiber loaded with silver ions, copper ions, or zinc ions; the blending ratio of flame-retardant sliver and antibacterial accompanying fiber is determined by an optimization algorithm, and the specific formula is as follows: ; in, The blending ratio of flame-retardant wool tops is %, with a value range of 70%~90%; FRreq is the preset flame-retardant performance index of the fabric, limiting oxygen index (LOI), with a value range of ≥32%; FRb is the flame-retardant performance index of the antibacterial accompanying fibers, limiting oxygen index (LOI), with a value range of 18%~22%; FRf is the flame-retardant performance index of the flame-retardant wool tops, limiting oxygen index (LOI), with a value range of ≥38%; the blending ratio of antibacterial accompanying fibers is... The value ranges from 10% to 30%.

8. The method for manufacturing a wool blend flame-retardant fabric according to claim 7, characterized in that: The bio-based permanent antibacterial fiber is prepared by chemically bonding natural antibacterial active substances with the fiber matrix, and the metal-based permanent antibacterial fiber is prepared by introducing antibacterial metal ions into the fiber surface and interior through ion exchange or covalent grafting. The antibacterial effect of both antibacterial fibers can withstand more than 50 standard washes without degradation.

9. The method for manufacturing a wool blend flame-retardant fabric according to claim 6, characterized in that: In S4, the drawing process adopts a two-stage blending process, with the machine speed controlled at 300~400m / min and the basis weight controlled at 4~6g / m; the draft ratio of the roving process is 5~8 times, and the draft ratio of the spinning process is 15~20 times, to ensure the uniform distribution of fibers in the blended fabric.

10. The method for manufacturing a wool blend flame-retardant fabric according to claim 6, characterized in that: In S5, the flame retardant performance test specifically includes: limiting oxygen index (LOI) ≥ 32%, no dripping, and no smoldering; the antibacterial performance test specifically includes: inhibition rate of ≥ 90% against Escherichia coli and Staphylococcus aureus; the appearance quality test includes color fastness test, with color fastness to soap washing and color fastness to rubbing both ≥ 4 grades, no pattern deformation, and no fiber damage.

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