Manufacturing method of super-soft polyester woven label trademark and woven label trademark

Abstract

The application relates to the field of woven label manufacturing technology, in particular to a super-soft polyester woven label manufacturing method and a woven label, which specifically comprises the following steps: weaving to obtain a base cloth; performing anti-migration modification treatment on the base cloth to obtain a to-be-cut cloth; performing ultrasonic wave cutting and slitting on the to-be-cut cloth to obtain a to-be-finished cloth; performing soft finishing and pre-fixing on the to-be-finished cloth to obtain a to-be-transitioned cloth; performing hot air drying on the to-be-transitioned cloth to obtain a to-be-set cloth; performing pre-shrinking and gradient setting on the to-be-set cloth to obtain a finished cloth; and performing shearing on the finished cloth to obtain a woven label product, so that the dye in the polyester fiber does not migrate and the softness of the woven label is not damaged even if high-temperature heat processing is performed on the dark label.

Description

Technical Field

[0001] This application relates to the field of woven label manufacturing technology, and in particular to a method for processing and manufacturing ultra-soft polyester woven labels and the woven label itself. Background Technology

[0002] Woven labels are essential identification carriers for clothing and other textiles, used to display brand information and size data. With the rapid expansion of niche markets such as intimate apparel, children's clothing, and high-end seamless sportswear, consumers' demands for zero foreign body sensation and high comfort when wearing textiles next to the skin have increased. The stiff feel, itchy edges, and strong foreign body sensation of traditional polyester woven labels have become core quality control bottlenecks for high-end apparel brands. Ultra-soft polyester woven labels have emerged to address this need. Through raw material matching, structural design, and process optimization, they achieve superior softness and a non-itchy wearing experience, becoming a core entry-level standard for high-end intimate apparel.

[0003] For example, the soft woven label and its preparation method, with announcement number CN115613190B, uses high-shrinkage yarn and cotton yarn as weft yarn and low-elasticity polyester yarn as warp yarn. Through the layered structure design of the edge locking area, the soft and non-melting cotton yarn covers the hardened cut edge formed by the high-shrinkage yarn after heat cutting. Combined with the soaking and ironing process of resin finishing agent and hydrophilic softener, the woven label can achieve the goal of not fraying the edges while maintaining a basic soft hand feel.

[0004] However, the aforementioned woven labels undergo high-temperature ironing and drying at 130-160℃ during processing. The disperse dyes in the polyester fibers are prone to thermal migration, which not only causes uneven fabric appearance, color deviation, and white showing at the cut edges, resulting in a significant decrease in product yield, but also damages the fluffy and low-elastic structure of the polyester fibers, leading to an abnormal increase in fiber crystallinity. This causes irreversible hardening of the woven label's hand feel and ultimately destroys its ultra-flexible properties, which is even more serious in dark-colored woven labels. Summary of the Invention

[0005] In order to prevent dye migration within the polyester fibers from damaging the softness of the woven label even when the dark-colored label is subjected to high-temperature heat treatment, this application provides a method for processing and manufacturing an ultra-soft polyester woven label and the woven label itself.

[0006] Firstly, the technical solution provided in this application for a method of processing and manufacturing an ultra-soft polyester woven label trademark is as follows.

[0007] A method for processing and manufacturing ultra-soft polyester woven labels specifically includes the following steps.

[0008] S1. Weaving to obtain the base fabric;

[0009] S2. The base fabric is subjected to anti-migration modification treatment to obtain the fabric to be cut;

[0010] S3. The fabric to be cut is ultrasonically cut into strips to obtain the fabric to be processed.

[0011] S4. Soften and pre-fix the fabric to be processed to obtain the transition fabric;

[0012] S5. The fabric to be transitioned is dried with hot air to obtain the fabric to be shaped.

[0013] S6. Pre-shrink and gradient-set the fabric to be shaped to obtain the finished fabric;

[0014] S7. Cut and fold the finished fabric to obtain the woven label.

[0015] By adopting the above technical solution, through the entire process of S2 and S4 pretreatment, S5 heat treatment and S6 structural shaping, a long-lasting protection system for the anti-dye migration and softness of dark ultra-soft polyester woven labels has been systematically constructed. This solves the problems of fabric surface discoloration and whitening at the cut edges caused by the thermal migration of disperse dyes after high-temperature heat treatment of dark woven labels, as well as the irreversible hardening of the hand feel caused by the damage of the fiber's loose structure due to dye migration. At the same time, the entire process takes into account the edge sealing of the woven label to prevent fraying, dimensional stability and adaptability to high-speed mass production, and can stably meet the dual core requirements of high color fastness and ultra-softness without itching for high-end intimate apparel.

[0016] Optionally, S2 first undergoes plasma treatment, then sprays a composite barrier coating liquid, and then performs infrared crosslinking curing at 100-110℃.

[0017] By adopting the above technical solution, a dense and highly adhesive nanoscale dye blocking network was constructed on the surface of polyester fiber, which blocked the channel for disperse dye to migrate to the fiber surface during high-temperature heat processing from the root, and suppressed the risk of dye thermal migration in dark-colored woven labels from the material end.

[0018] Plasma activation significantly improves the adhesion between the coating and the fiber, preventing the coating from falling off and failing in subsequent processes; infrared curing at 100-110℃ only heats the surface of the fiber, which achieves full cross-linking of the coating without damaging the fluffy structure of the fiber and without affecting the ultra-soft feel of the woven label.

[0019] Optionally, in step S3, the cut edge is pressed and cooled simultaneously with the cutting. The pressing temperature is 115-120℃, and the temperature of the cut edge is controlled to drop below 100℃ within 0.5s during cooling.

[0020] By adopting the above technical solution, the high-shrinkage weft polyester yarn inside is thermally shrunken inward, so as to gather the sealed edge layer formed by the melting inside the cut edge inward, while the surface yarn naturally turns outward to cover it, forming a self-softening edge sealing structure that is hard inside and soft outside, reducing the problem of itching at the cut edge under ultra-thin structure.

[0021] At the same time, the high-temperature dwell time in the cutting area is shortened, which inhibits the thermal migration of disperse dyes during the cutting process from the process end, reduces the problems of white exposure and color deviation that are most likely to occur in dark woven labels, and at the same time, rapid cooling avoids excessive melting and crystallization of polyester fibers, prevents hardening of the cutting edge, and retains the ultra-soft and non-itchy feel of the woven label cutting edge.

[0022] While controlling temperature and color, it can still ensure the full melting and sealing of polyester fibers at the cut edges, so that the woven label will not fray or have fuzz after washing.

[0023] Optionally, in step S4, a softener is sprayed first, followed by infrared crosslinking pre-fixation at 100-110°C.

[0024] By adopting the above technical solution, precise spraying achieves uniform liquid application of softener on the fabric surface, ensuring the consistency of the soft hand feel across the entire woven label. Then, through 100-110℃ short-wave infrared pre-fixation, the self-crosslinking softener completes 90% crosslinking and fixation in advance, forming stable hydrogen bond anchoring with polyester fibers, avoiding thermal migration and loss of softener during subsequent high-temperature setting processes, and effectively locking in the ultra-soft hand feel of the woven label for a long time.

[0025] Meanwhile, the temperature of 100-110℃ is far lower than the sublimation initiation temperature of disperse dyes, which makes it less likely to cause dye thermal migration and will not damage the anti-migration barrier coating formed in the S2 process. This achieves a balance between high color fastness and ultra-soft hand feel for dark woven labels, and can also reduce mass production problems such as roll area silicone, uneven hand feel and yellowing caused by free silicone oil.

[0026] Optionally, step S5 involves air drying at 80-85°C for 15-20 seconds.

[0027] By adopting the above technical solution, the moisture regain of the woven label is precisely controlled within the safe range of 6%-8%, eliminating the interference of humid heat steam generated by the rapid vaporization of fabric moisture in the subsequent pre-shrinking and high-temperature setting stages, avoiding the migration of disperse dyes and fabric surface discoloration under high temperature and high humidity conditions, and further enhancing the color fastness stability of dark woven labels.

[0028] It also prevents the fabric from sticking together in the storage rack, which would cause it to shrink and fail. This ensures that the high-shrinkage yarn forms an ultra-soft structure that is tight on the inside and loose on the outside, fully preserving the fluffy feel of the woven label. It also avoids the problem of the finished product feeling sticky due to the redissolution of the coating and softener under high temperature and humidity.

[0029] Optionally, in step S6, the pre-shrinking tension is controlled to be 0.5-1N, the temperature is controlled to be 80-100℃, and the shrinkage time is 30-40s.

[0030] By adopting the above technical solution, the yarn can be pre-shrinked in a controlled manner without stretching or restraint, forming a tight outer structure within the edge-locking area. This not only ensures the anti-fraying performance of the woven label after washing, but also maximizes the retention of fiber bulk, achieving an ultra-soft hand feel for the woven label itself. At the same time, the low-temperature hot air environment of 80-100℃ is far below the sublimation initiation temperature of disperse dyes, making it less likely to cause dye thermal migration. It can also remove residual moisture from the fabric, avoiding hygroscopic migration during subsequent high-temperature setting. In addition, it can completely release the internal stress during the weaving and cutting process, preventing fabric wrinkling and weft-side ruffles, and improving the smoothness of the finished product.

[0031] Optionally, in step S6, the tension of the gradient setting is linearly increased to 4N within 3s, the temperature is increased to 135-145℃ at 2℃ / s, the temperature is kept constant for 30s, and then the temperature is reduced to below 60℃ at 3℃ / s.

[0032] By adopting the above technical solution, the tension is linearly increased to 4N within 3 seconds, eliminating the tension step impact, avoiding the stretching and destruction of the ultra-soft and fluffy structure formed by pre-shrinkage, and effectively locking in the ultra-soft feel of the woven label.

[0033] The temperature is raised at a constant rate of 2℃ / s to 135-145℃ for constant temperature setting, which avoids the violent migration of dyes in the fiber caused by a sudden temperature rise. At the same time, it precisely controls the fiber size stability and can also complete the final cross-linking and curing of the anti-migration coating, further enhancing the dye blocking effect.

[0034] The fabric is cooled at a constant rate of 3℃ / s to below 60℃ before being produced, which avoids abnormal increases in fiber crystallinity or hardening of the hand feel caused by a sudden drop in temperature. At the same time, it locks in the dispersed dyes in the fibers and reduces dye migration during the cooling process.

[0035] Optionally, the hot melt shearing temperature in S7 is 190-210℃.

[0036] By adopting the above technical solution, the folding and bonding and smooth cutting edge can be achieved by only slightly melting the surface layer of polyester fiber. This temperature is much lower than the sublimation temperature of disperse dyes, which is not likely to cause thermal degradation and thermal migration of dyes at the cutting and folding position, thus eliminating the common problems of yellowing and white exposure at the cutting and folding edge of dark woven labels.

[0037] At the same time, it avoids hardening of the cut edges caused by excessive melting and crystallization of fibers, and fully preserves the ultra-soft and non-itchy feel of the entire woven label.

[0038] Secondly, the super-soft polyester woven label trademark provided in this application adopts the following technical solution.

[0039] An ultra-soft polyester woven label trademark is prepared according to the above-mentioned processing and manufacturing method for an ultra-soft polyester woven label trademark.

[0040] Optionally, it includes a main body area and a seam overlock area, with the weft density increasing linearly by 20% from the main body area to the seam overlock area, and the thickness of the main body area and the seam overlock area controlled between 0.1-0.14mm.

[0041] By adopting the above technical solution, a fabric structure with a loose inner layer and a dense outer layer is formed. The edge-locking area is naturally dense, and excellent anti-fraying edge effect can be achieved without high-power ultrasonic cutting and high-temperature heat melting. This greatly reduces the heat input of heat processing, reduces the heat migration of disperse dyes caused by high temperature from the root, and reduces the white exposure at the cut edge of dark woven labels.

[0042] Meanwhile, the single-layer structure precisely controls the thickness of the woven label between 0.1-0.14mm, achieving an ultra-thin and seamless effect. The loose inner and dense outer structure not only ensures the edge locking and anti-fraying performance, but also maximizes the fiber fluffiness of the main body area, achieving an ultra-soft and close-fitting feel.

[0043] In addition, this single-layer structure has no complex jacquard operation, resulting in a low defect rate, improved mass production efficiency, and no risk of white showing due to color difference between upper and lower yarns. The appearance consistency and mass production stability of dark woven labels are greatly improved.

[0044] In summary, this application includes at least the following beneficial effects:

[0045] Through anti-migration modification treatment of plasma activation after weaving, composite barrier coating spraying and infrared cross-linking curing, a dense and stable dye barrier network is constructed on the fiber surface, which inhibits the thermal migration of disperse dyes during the heat treatment of dark woven labels, solves the industry pain points of fabric surface mottled, color deviation and white exposure at the cut edge, and significantly improves the product's color fastness indicators such as sublimation resistance and dry and wet rubbing.

[0046] Combined with the ultrasonic cutting and slitting process that uses instant cooling, it ensures that the cut edges are melted and sealed and prevents the edges from fraying after washing. It also significantly reduces the damage of heat input to the dye and fiber structure, and avoids the hardening of the cut edges and irreversible loss of hand feel.

[0047] Subsequent softening finishing through softener spraying and infrared cross-linking pre-fixation achieves stable anchoring and cross-linking of the softener on the fiber surface, avoiding problems such as free silicone oil migration, yellowing and water washing loss, and ensuring the long-term maintenance of the ultra-soft feel of the woven label.

[0048] By precisely controlling the fabric moisture regain through a hot air drying process at 80-85℃ and for 15-20 seconds, the problems of damp heat adhesion, uncontrolled shrinkage, and tension oscillation shutdown caused by sudden changes in moisture content between processes are avoided, providing a stable process foundation for subsequent setting processes.

[0049] By using a loose pre-shrinking process with low tension of 0.5-1N, 80-100℃ and 30-40s, combined with a gradient heating and cooling process with linear tension up to 4N within 3s, the high-shrinkage yarn is pre-shrinked without constraints and with a tight inner and loose outer edge structure to balance anti-fraying performance and fluffy and super soft hand feel. This fully releases the internal stress of weaving to avoid fabric wrinkling and weft flutter problems. It also eliminates the tensile damage to the pre-shrinking structure caused by tension step impact, accurately controls the dimensional stability of the finished product, and completes the final cross-linking and curing of the barrier coating, further consolidating the anti-dye migration effect.

[0050] The precise hot melt shearing and folding process at the end of the polyester at 190-210℃ achieves smooth cut edges and stable folding and bonding within the safe heat processing window of polyester, avoiding edge hardening, yellowing and dye degradation caused by excessive melting, and fully preserving the ultra-flexible properties of the finished product.

[0051] The matching ultra-thin single-layer overlock structure, with a 20% linear increase in weft density from the main body area to the overlock area and an overall thickness controlled at 0.1-0.14mm, meets the ultra-thin thickness requirements of seamless clothing. At the same time, it achieves a performance balance between the dense anti-fraying edge of the overlock area and the fluffy and ultra-soft edge of the main body area through the weft density gradient, solving the core pain points of ultra-thin woven labels such as itchy edges, frayed edges, excessive thickness, and exposed edges. Attached Figure Description

[0052] Figure 1 This is a flowchart illustrating the steps involved in the processing and manufacturing of ultra-soft polyester woven labels.

[0053] Figure 2 This is a side view of an ultra-soft polyester woven label used to show the change in weft density from the main area to the overlock area.

[0054] Explanation of reference numerals in the attached diagram: 1. Main area; 2. Edge-locking area. Detailed Implementation

[0055] The present application will be further described in detail below with reference to the accompanying drawings.

[0056] This application discloses a method for processing and manufacturing ultra-soft polyester woven labels, referring to... Figure 1 Specifically, it includes the following steps.

[0057] S1. Weaving to obtain the base fabric.

[0058] The warp yarns can be made of 75D / 36F colored low-elastic polyester DTY, and the weft yarns can be made of 50D / 72F high-shrinkage polyester DTY. The width of the overlock area is 0.8-1mm. The thickness of the base fabric is controlled between 0.1-0.14mm. When packing the fabric after weaving, the tension is controlled at 5-10N to avoid stretching and deformation of the fabric surface.

[0059] S2. The base fabric is subjected to anti-migration modification treatment to obtain the fabric to be cut.

[0060] First, the base fabric is continuously passed through the plasma treatment chamber at a speed of 5-8 m / min, with a treatment power of 100-150W. Both sides are treated simultaneously to introduce hydroxyl and carboxyl active sites on the surface of the base fabric fibers, thereby improving the adhesion of the coating.

[0061] The plasma-activated base fabric is immediately subjected to high-pressure micro-mist spraying at a pressure of 0.3-0.5 MPa. The spraying medium is a composite barrier coating liquid, which is a mixture of water-based nano-silica and polyurethane with a solid content of 5-8%.

[0062] Immediately after spraying, the base fabric undergoes short-wave infrared curing at 100-110℃ for 10-12 seconds. Short-wave infrared heating only heats the surface coating and fibers, eliminating the risk of overall thermal shrinkage. This temperature range allows at least 85% co-fusion of the waterborne polyurethane latex particles, forming a continuous and dense initial barrier network, while preventing the agglomeration of nano-silica caused by high temperatures. The remaining cross-linking is completed naturally in the subsequent S6 setting stage, reducing issues such as coating false drying, high-temperature flow collapse, and roller sticking. Ultimately, a uniform porous barrier coating of 50-100 nm is formed on the fabric fiber surface, inhibiting the thermal migration of disperse dyes during subsequent thermal processing.

[0063] S3. The fabric to be cut is ultrasonically cut into strips to obtain the fabric to be processed.

[0064] The ultrasonic frequency is 30-35kHz, the generator rated power is 600-1000W, the amplitude is 10-20μm, the cutting conveyor speed is 6-8m / min, and the running tension is stably controlled at 15-18N.

[0065] After cutting, the yarn is pressed simultaneously at a temperature of 115-120℃. This causes the high-shrinkage polyester weft yarn inside to shrink inward, thus drawing the sealed edge layer formed by the melting inside the cut edge inward. At the same time, the surface yarn naturally turns outward to cover the edge, forming a self-softening edge sealing structure that is hard inside and soft outside, reducing the problem of itching at the cut edge in ultra-thin structures.

[0066] S4. Soften and pre-fix the fabric to be processed to obtain the transition fabric.

[0067] The fabric to be treated is atomized and sprayed at a speed of 5-8 m / min. The spraying medium is an aqueous solution of a self-crosslinking hydrophilic cationic silicone softener of 6-8 g / L. The liquid content of the fabric to be treated is controlled at 25-30%, without local over-wetting or water stains, which greatly reduces the subsequent drying load.

[0068] Immediately after spraying, the fabric to be finished is heated with short-wave infrared heat at 100-110℃ for 8-10 seconds. Short-wave infrared heating only heats the fiber surface, eliminating the risk of overall thermal shrinkage and preventing premature, disorderly shrinkage of high-shrinkage yarns. This temperature range allows the amino / epoxy groups of the softener to complete self-crosslinking and form hydrogen bonds with the polyester fiber surface, reducing problems such as silicone buildup on the rollers, uneven hand feel, and oxidative yellowing caused by free silicone oil entering the subsequent high-temperature setting stage.

[0069] S5. The fabric to be transitioned is dried with hot air to obtain the fabric to be shaped.

[0070] The hot air temperature is 80-85℃, the wind speed is 0.5-0.8m / s, the drying time is 15-20s, and the moisture regain of the fabric to be set is precisely controlled at 6-8%, eliminating the problems of rapid vaporization and fabric adhesion under high temperature relaxation environment.

[0071] S6. The fabric to be shaped is pre-shrinked and gradient-shaped to obtain the finished fabric.

[0072] The pre-shrinkage tension is controlled at 0.5-1N, the temperature at 80-100℃, and the shrinkage time at 30-40s, so that the high-shrinkage polyester can complete the controllable pre-shrinkage in an unrestrained state, forming a tight outer structure in the edge locking area, while removing residual moisture from the fabric.

[0073] After pre-shrinkage, the tension is smoothly transitioned to a constant 4N by a 3-second linear ramp. Then, the cavity temperature is raised to 135-145℃ at a constant heating rate of 2℃ / s and held at a constant temperature for 30 seconds to precisely control the overall dimensional stability of the fiber. At the same time, the final cross-linking and curing of the waterborne polyurethane coating is completed, forming a complete dye barrier network to prevent dye thermal migration caused by high temperature.

[0074] After the setting is completed, the temperature is reduced to below 60℃ at a constant cooling rate of 3℃ / s before the fabric is rolled out. This avoids uneven shrinkage or wrinkling of the finished fabric due to a sudden drop in temperature, and at the same time locks in the dispersed dyes in the fibers to prevent migration.

[0075] S7. Cut and fold the finished fabric to obtain the woven label.

[0076] The temperature of the hot melt folding shear is strictly controlled at 190-210℃, and the cutting frequency is 150-200 times / min. Within this temperature range, only the surface layer of polyester fiber is slightly melted, achieving a smooth cut edge and folding bonding without excessive melting and adhesion or blade sticking to the material. At the same time, it will not cause dye thermal degradation, softener deactivation, or damage to low-melting-point components. The cut edge does not yellow or harden, and retains an ultra-soft feel.

[0077] This application also discloses an ultra-soft polyester woven label trademark, as described in the embodiments. Figure 2It includes main body area 1 and edge locking area 2. The weft density of main body area 1 to edge locking area 2 increases linearly by 20%, and the thickness of main body area 1 and edge locking area 2 is controlled between 0.1-0.14mm.

[0078] The following description is based on specific embodiments and comparative examples.

[0079] Example 1:

[0080] The above-mentioned method for manufacturing ultra-soft polyester woven labels is used to manufacture ultra-soft polyester woven labels, except that the following relevant parameters are determined.

[0081] S2 and S4 are subjected to infrared cross-linking curing at 100℃;

[0082] S5 is air-dried at 80°C for 15 seconds.

[0083] The pre-shrinkage tension of S6 is controlled at 0.5N, the temperature is controlled at 80℃, the shrinkage time is 30s, and the temperature is increased to 135℃ at 2℃ / s during gradient setting.

[0084] The S7 hot melt shearing and bending temperature is 190℃;

[0085] The thickness of the main body area 1 and the edge-locking area 2 is 0.1mm.

[0086] Example 2:

[0087] The difference from Example 1 is that S2 and S4 are subjected to infrared crosslinking curing at 110°C;

[0088] S5 is air-dried at 85°C for 20 seconds;

[0089] The pre-shrinkage tension of S6 is controlled at 1N, the temperature is controlled at 100℃, the shrinkage time is 40s, and the temperature is increased to 145℃ at 2℃ / s during gradient setting.

[0090] The S7 hot melt shearing and bending temperature is 210℃;

[0091] The thickness of the main body area 1 and the edge-locking area 2 is 0.14mm.

[0092] Comparative Example 1:

[0093] The difference from Example 1 is that S2 is removed, that is, S3 is performed directly after S1 is completed.

[0094] Comparative Example 2:

[0095] The difference from Example 1 is that cooling in S3 and S5 are removed.

[0096] Comparative Example 3:

[0097] The difference from Example 1 is that S4 is removed.

[0098] Comparative Example 4:

[0099] The difference from Example 1 is that conventional equal-weft close-locking is used.

[0100] Comparative Example 5:

[0101] The difference from Example 1 is that the linear rise and fall of tension and temperature in S6 is removed.

[0102] Ten samples of the woven label trademarks obtained from the above embodiments and comparative examples were tested for the following indicators.

[0103] For the color fastness to sublimation, the test shall be conducted in accordance with GB / T 5718-1997 "Textiles - Tests for color fastness to sublimation", with test conditions of 180℃ / 30s. The color change gray scale of GB 250-2008 shall be used for grading, with grade 1 being the worst and grade 5 being the best.

[0104] The cut edge exposure level is determined by observing the cut edge with a 10x magnifying glass. Level 0 indicates no exposure, Level 1 indicates very slight dot-like exposure, Level 2 indicates slight linear exposure, Level 3 indicates obvious exposure, Level 4 indicates severe exposure, and Level 5 indicates full exposure. The lower the level number, the better the anti-exposure effect.

[0105] The edge irritation score was determined by 5 testers who rubbed the cut edge of the sample against the skin on the inside of the wrist 10 times at a uniform speed and gave a blind rating of 1-10. 1 point was for strong itching and stinging, and 10 points was for no itching at all. The average score of the 5 people was taken.

[0106] After washing, the edge fraying level is determined by observing the cut edge with a 10x magnifying glass after 50 industrial washes and 1000 Martindale rubbing cycles. Level 1 indicates severe fraying, while Level 5 indicates no fraying at all. The higher the level number, the better the edge fraying performance.

[0107] The specific results are shown in Table 1.

[0108] Table 1:

[0109]

[0110] Comparing Comparative Example 1 and Example 1, S2 is the key step in solving the core pain points of dark woven labels. It can construct a nanoscale dye blocking network on the surface of polyester fibers, inhibiting the thermal migration of disperse dyes during high-temperature heat processing from the material level, which directly determines the sublimation fastness and edge-cutting anti-whitening performance of dark woven labels.

[0111] Comparing Comparative Example 2 and Example 1, the cooling in S3 significantly shortens the high-temperature dwell time at the cut edge, suppressing dye thermal migration during the cutting process from the process end, while avoiding edge hardening caused by excessive melting and crystallization of polyester fibers. This is key to balancing edge whitening and a non-itchy feel. S5 avoids dye migration and fabric discoloration caused by humid steam during high-temperature setting, and solves the problems of fabric adhesion and free shrinkage failure, ensuring the uniformity of edge sealing and ultimately improving the anti-fraying performance after washing. The two steps constitute a synergistic system, and neither can be omitted.

[0112] Comparing Comparative Example 3 and Example 1, S4 enables the self-crosslinking softener to form stable hydrogen bonds with the polyester fibers, completing 90% of the crosslinking and fixation ahead of time. This avoids thermal migration or loss of the softener during subsequent high-temperature setting, which is the core of achieving long-lasting maintenance of the ultra-soft feel of the woven label. In addition, the process temperature is much lower than the sublimation initiation temperature of disperse dyes, which will not cause dye thermal migration. At the same time, it can reduce problems such as roller area silicone, uneven hand feel, and yellowing caused by free silicone oil.

[0113] Comparing Comparative Example 4 and Example 1, the weft density gradient structure of this application achieves a naturally dense edge lock, achieving excellent anti-fraying effect without high-power ultrasonic cutting. This avoids dye thermal migration and edge hardening caused by high-power cutting, and structurally solves the problems of itchy edges, frayed edges after washing, and white showing at the cut edges in ultra-thin woven labels. In addition, without complex jacquard operations, the thickness of the woven label can be stably controlled within the ultra-thin range of 0.1-0.14mm, while eliminating the risk of white showing due to color difference between upper and lower yarns. This achieves a balance of performance in terms of ultra-thinness and seamlessness, ultra-softness and non-itchiness, anti-fraying, and anti-white showing.

[0114] Comparing Comparative Example 5 and Example 1, S6 allows high-shrinkage yarn to complete controllable pre-shrinkage in an unrestrained state, forming a self-softening edge-sealing structure that is tight inside and loose outside in the edge-locking zone. This ensures both the anti-fraying performance after washing and maximizes the retention of fiber bulk. In addition, the gradient setting process eliminates the impact of tension step, preventing the bulky structure formed by pre-shrinkage from being stretched and destroyed, thus locking in the ultra-soft hand feel for a long time. It also avoids the violent dye migration and abnormal increase in fiber crystallinity caused by sudden temperature changes through uniform heating / cooling, thus balancing dimensional stability, high color fastness, and ultra-soft hand feel.

[0115] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method for processing and manufacturing ultra-soft polyester woven labels, characterized in that: Specifically, the following steps are included: S1. Weaving to obtain the base fabric; S2. The base fabric is subjected to anti-migration modification treatment to obtain the fabric to be cut; S3. The fabric to be cut is ultrasonically cut into strips to obtain the fabric to be processed. S4. Soften and pre-fix the fabric to be processed to obtain the transition fabric; S5. The fabric to be transitioned is dried with hot air to obtain the fabric to be shaped. S6. Pre-shrink and gradient-set the fabric to be shaped to obtain the finished fabric; S7. Cut and fold the finished fabric to obtain the woven label.

2. The method for processing and manufacturing an ultra-soft polyester woven label according to claim 1, characterized in that: The S2 process involves plasma treatment followed by spraying a composite barrier coating liquid, and then infrared crosslinking curing at 100-110℃.

3. The method for processing and manufacturing an ultra-soft polyester woven label according to claim 1, characterized in that: In step S3, the cut edge is pressed and cooled simultaneously with the cutting. The pressing temperature is 115-120℃, and the temperature of the cut edge is controlled to drop below 100℃ within 0.5s during cooling.

4. The method for processing and manufacturing an ultra-soft polyester woven label according to claim 1, characterized in that: The process begins with spraying a softener onto the S4 component, followed by infrared cross-linking pre-fixation at 100-110°C.

5. The method for processing and manufacturing an ultra-soft polyester woven label according to claim 1, characterized in that: The S5 process involves air drying at 80-85°C for 15-20 seconds.

6. The method for processing and manufacturing an ultra-soft polyester woven label according to claim 1, characterized in that: In the S6, the pre-shrinkage tension is controlled at 0.5-1N, the temperature is controlled at 80-100℃, and the shrinkage time is 30-40s.

7. The method for processing and manufacturing an ultra-soft polyester woven label according to claim 6, characterized in that: In S6, the tension of the gradient setting is linearly increased to 4N within 3s, the temperature is increased to 135-145℃ at 2℃ / s, the temperature is kept constant for 30s, and then the temperature is reduced to below 60℃ at 3℃ / s.

8. The method for processing and manufacturing an ultra-soft polyester woven label according to claim 1, characterized in that: The hot melt shearing temperature in S7 is 190-210℃.

9. A super-soft polyester woven label trademark, characterized in that: The product is prepared according to any one of claims 1-8.

10. The ultra-soft polyester woven label trademark according to claim 9, characterized in that: It includes a main body area (1) and a edging area (2). The weft density of the main body area (1) to the edging area (2) increases linearly by 20%, and the thickness of the main body area (1) and the edging area (2) is controlled between 0.1-0.14 mm.

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