Using a beam dyeing machine to dye high-needle ultra-fine and ultra-thin plain weave can avoid many problems such as snagging, layering, and chicken feet. However, the current dyeing process produces color differences between the inner and outer layers, which seriously restricts this application. The selection of cloth loading volume, flow rate setting and rolling density control are all important factors affecting this issue. Adjust the cloth loading amount, flow rate, and rolling density, and explore how to control the color difference between the inner and outer layers dyed by the beam dyeing machine in the actual production process.
Dyeing factories generally use overflow cylinders for dyeing weft-knitted plain fabrics, and the process is relatively simple. However, high-needle, ultra-fine and ultra-thin weft-knitted plain fabrics are prone to snagging and crushing during the dyeing and finishing process. , chicken feet and other quality problems, so high needle count, ultra-fine, ultra-thin weft-knitted plain fabrics can be dyed with beam machines.
The beam dyeing machine rolls the fabric on the reel of a porous drum and fills it in a pressure cooker. It uses a high-lift, large-flow professional chemical pump to circulate from the inside of the hollow reel to the fabric layer from the inside to the outside. The cycle can be reversed to allow the dye liquor to penetrate the rolled fabric and be dyed in a high temperature and high pressure dye bath. The advantage of the high-temperature and high-pressure beam dyeing machine is that the dyed fabric is smooth and crisp without wrinkles. The dyeing effect on diamond patterns and striped patterns is better than rope dip dyeing and liquid flow dyeing. However, it is easy to cause color difference between the inner and outer layers when dyeing with a beam dyeing machine. In addition to improving the process conditions, we will now discuss how to control the color difference between the inner and outer layers dyed by a beam dyeing machine by changing some parameters in the actual production process.
01Experiment
1.1 Materials and Equipment
Materials:
Nylon PN60026（53%NYLON+47%LYCRA, width140 cm, mass per unit area50 g/㎡).
Device:
CBS1450Beam dyeing machine [Fuxin Dyeing and Finishing Machinery (Shenzhen) Co., Ltd.], winding machine, beam dyeing machine, computer color measuring and matching instrument.
1.2 Dyeing process
Craft recipe:
Water softenerNORM157 0.35g/L, sodium acetate0.5 g/L, uniform DyeACID16 1.5% , glacial acetic acid (HAC) 0.25g/L , SNACID YELLOW L058 0.285% , SNACID RED L544 0.046% , span>SNACID GRAY L055 0.360% , dyeing temperature98 ℃, holding time20min, liquor ratio1:20.
The process flow is as follows:
1.3 Experimental Methods
1.3.1 The effect of dye liquor flow on the color difference between the inner and outer layers of dyeing
Divide the gray cloth that has been degreased and calibrated into 3 portions, roll the cloth under the same rolling conditions and then divide into 3 tanks are used for dyeing, and the dye liquor flow rate (pump rate) is set to 160 and 220 respectively. , 280 m³/h, after dyeing, dry the cloth out of the vat, starting from the outer layer of the warp beam every 100m Sampling, the first sample is a1, followed by a2, span>a3, a4, a5, a6, a7, after sampling is completed, use a1 as the standard , use a computer color measuring and matching instrument to measure the color difference.
1.3.2 The effect of rolling density on the color difference between the inner and outer layers of dyeing
Divide the degreased and gray fabric into 3 portions, change the tension when rolling the fabric, and calculate the rolling volume after rolling the fabric The densities are 0.28 and <s respectively.As the density increases, the color difference between the inner and outer layers increases. This can be understood as increasing the rolling density, which is not conducive to the diffusion of dye molecules, resulting in an increase in the color difference between the inner and outer layers.
The density of the warp beam is too small, and the entire warp beam will fall during the dyeing process. The upper disc of the warp beam will be separated from the yarn, causing the local cloth surface to be disrupted, causing creases and color stains. and other quality problems; the density of the warp beam is too high, and during the dyeing process, the entire warp beam will result in a large amount of color in the inner layer, a darker color, a small amount of color in the middle, a lighter color, and inconsistent overall cloth color. The density of the warp beams in the same dye vat should be consistent. If the density is too high, the dyeing will be opaque or the amount of color obtained will be small, resulting in color flowers; if the density is too small, the amount of color obtained will increase or the local fabric surface will be disrupted, resulting in quality problems such as color flowers, creases, etc. question.
2.3 The effect of cloth loading on the color difference between the inner and outer layers of dyeing
It can be seen from the table 3 and the figure 3 that the same sampling pointDEThe values from large to small are 150, 100 , 50 kg. It can be seen that increasing the cloth loading amount can be understood as an increase in the resistance to the movement of dye molecules, which is not conducive to the diffusion of the dye solution and increases the color difference between the inner and outer layers.
At the same time, the dyeing bath ratio is also very important. When using an overflow tank or an airflow tank, the dyeing bath ratio is generally above 1:20, while the beam dyeing bath ratio is much larger than normal dyeing. Some dyeing bath ratios Up to 1:40, 1:60, 1:80, or even1∶100, seriously affects the dyeing quality, makes duplicate samples more difficult, resulting in small color yield, light color, and difficulty in controlling the color light. question. An extremely large liquor ratio will also cause a waste of dyeing materials and additives and increase dyeing costs. Research has found that combining several varieties of warp beams can increase the winding amount and reduce the bath ratio; add fillers to the inner layer of the warp beam to increase the number of dyes and reduce the bath ratio; make fake warp beams as fillers to reduce the amount of water and reduce the bath ratio. Compare. All of the above methods can achieve good results.
03Conclusion
1. Increasing the dye liquor flow rate will help improve the color difference between the inner and outer layers, but it will increase energy consumption and cost. High dye flow is prone to ghosting (similar to water ripples). For nylonPN60026 (53% NYLON+47% LYCRA , width140 cm, mass per unit area50 g/m² ) and similar fabricsCBS1450When dyeing with the beam dyeing machine, the dye liquor flow rate is controlled at around 220 m³/h to make the inside and outside of the dyed fabric The layer color difference achieves a more ideal effect.
2. The rolling density should be controlled at 0.33 kg/m³ to keep the color difference between the inner and outer layers within an acceptable range. Excessive rolling density will increase the There is a large color difference between the inner and outer layers, and it is easy to appear“ghost“ in actual production, and the rolling density is too small. Fabric slips easily.
3. Reducing the amount of cloth loaded can reduce the color difference between the inner and outer layers of the beam dyeing machine, thereby effectively controlling the color difference between the inner and outer layers and achieving good dyeing results; however, too small a load of cloth is not conducive to the increase in output. It is more appropriate to control the cloth loading amount at around 150 kg.
4. There are many factors that affect the quality of beam dyeing products, including dye liquor flow, rolling density, cloth loading, etc. Production practice has proved that grasping these links can improve the accuracy and stability of beam dyeing, and greatly improve the first-time success rate of dyeing. Warp beam dyeing has many advantages, but it is also very risky. The process is complex and it is difficult to repair problems if they occur. Therefore, the preparation work before dyeing must be sufficient to ensure a successful dyeing.
Only with 100% can the dyeing be guaranteed to be successful in the first time.
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