CN106065530B - 一种全棉织物还原染料的短湿蒸轧染工艺 - Google Patents
一种全棉织物还原染料的短湿蒸轧染工艺 Download PDFInfo
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- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/22—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using vat dyestuffs including indigo
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- D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
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Abstract
本发明公开了一种全棉织物还原染料的短湿蒸轧染工艺,包括如下工艺:S1、浸轧染液,按浴比1:5‑10将所述全棉织物浸轧染液,浸轧温度为20‑40℃,轧余率为85‑95%;S2、加入助剂,利用高给液装置供给助剂,所述全棉织物上助剂带液率为90‑100%;S3、快速汽蒸,使用饱和蒸汽进行快速汽蒸,其中,蒸箱的温度为90‑110℃,蒸箱湿度为99‑100%,汽蒸时间为1.5‑2min;S4、高温水洗;S5、氧化处理;S6、皂洗。所述全棉织物还原染料的短湿蒸轧染工艺,其不仅具有匀染性好,色牢度高的优点,而且工艺简单,环保健康。
Description
技术领域
本发明涉及印染技术领域,尤其涉及一种全棉织物还原染料的短湿蒸轧染工艺。
背景技术
还原染料染色以其优异的耐漂洗、耐晒色牢度,一直是人们染棉类染色产品的最爱。目前国际印染市场对还原染料染色棉麻织物需求量逐步增大。但由于其要求高,采用一般流体浸染方式进行全棉织物还原染料染色根本无法满足这一要求。
这是由于,一方面,还原染料本身都不溶于水或者微溶于水,合成出的还原染料颗粒较大,不能直接由于印染行业,即便经过研磨加工,使得染料颗粒分散,但是由于染料颗粒具有重新聚集的倾向,因此即便形成一定的分散效果,但由于染料分散体的稳定性较差,还原染料浸染工艺的匀染性和色牢度也随之较差。另一方面,现有技术中采用“常规还原染料悬浮体轧染”方式进行棉麻织物染色,在打底烘燥过程中,由于染料向毛圈上部泳移,致使全棉织物底部发白,客户也无法接受。
发明内容
基于背景技术中存在的问题,本发明提出了一种全棉织物还原染料的短湿蒸轧染工艺,其不仅具有匀染性好,色牢度高的优点,而且工艺简单,环保健康。
本发明提出了一种全棉织物还原染料的短湿蒸轧染工艺,包括如下工艺:
S1、浸轧染液,按浴比1:5-10将所述全棉织物浸轧染液,浸轧温度为20-40℃,轧余率为85-95%,所述染液的配方包括:染料15-25g/L、分散剂3.0-9.0g/L、渗透剂T 1.0-2.0g/L;
S2、加入助剂,利用高给液装置供给助剂,所述全棉织物上助剂带液率为90-100%,所述助剂的配方包括:还原剂5-20g/L、烧碱20-60g/L、螯合分散剂1-1.5g/L;
S3、快速汽蒸,使用饱和蒸汽进行快速汽蒸,其中,蒸箱的温度为90-110℃,蒸箱湿度为99-100%,汽蒸时间为1.5-2min;
S4、高温水洗,水洗温度为60-80℃,水洗时间3-5min;
S5、氧化处理,利用双氧水氧化液在温度为40-60℃,pH值为9-10的条件下氧化15-20min,接着用5-30℃的清水冲洗干净;
S6、皂洗,利用皂洗液在温度为90-98℃,pH值为10-11的条件下皂洗15-25min,接着用50-60℃的清水冲洗干净。
优选地,在S1中,所述分散剂的配方按重量份包括:木质素磺酸钠12-18份、聚乙烯吡硌烷酮K-30 4-10份、纳米二氧化硅3-5份、亚硫酸钠1-3份、聚丙烯醇10-20份、平平加O8-10份、水30-60份。
优选地,所述分散剂的制备工艺包括,按配比将各组分混合,搅拌均匀后得到所述分散剂。
优选地,所述还原剂的制备方法包括:将还原糖加入水中搅拌均匀,滴加乙二醛溶液,并加入磷酸钠调节pH为9-10,在40-60℃下搅拌反应1-2h,加入焦亚硫酸钠、保险粉和二氧化硫脲,在70-95℃下搅拌反应2-4h,干燥,得到所述还原剂。
优选地,还原糖、乙二醛溶液、焦亚硫酸钠、保险粉和二氧化硫脲的重量配比为:1:0.01-0.1:1-1.5:0.6-0.8:0.2-0.4;优选地,所述还原糖为葡萄糖、果糖、半乳糖、乳糖和麦芽糖中的至少一种。
优选地,在S3中,蒸汽压力为800-1000Pa。
优选地,在S5中,双氧水氧化液中含有用量为0.5-3g/L的35-40wt%双氧水。
优选地,在S6中,所述皂洗液包括:净洗剂209 1-3g/L;纯碱1-2g/L。
优选地,皂洗工艺后,还包括烘干,烘干温度为80-100℃,烘干时间为5-10min。
本发明中,针对所述全棉织物的表面性能,提出了一种利用还原染料进行短湿蒸轧染工艺,所述工艺主要分为,染料还原、染料上染、染料氧化、皂洗四个阶段,首先,本发明中利用还原染料加上分散剂等形成有利于织物浸轧的染液,所述分散剂通过特定种类的表面活性剂和各种助剂复配形成,可以在染液中与染料形成染料微悬浮体,该微悬浮体聚集程度均一,且与棉纤维之间作用力增大,即可在染色低温区域对面纤维快速均匀吸附,因此不仅大大缩短了还原染料的研磨时间,而且由此形成的微悬浮体可在染浴中循环并均匀吸附和沉积在纤维上,并可向纤维内部进行扩散;此后,本发明中所述短湿蒸轧染工艺,为了避免采用“常规还原染料悬浮体轧染”方式进行全棉织物染色,在打底烘燥过程中,由于染料向毛圈上部泳移,致使全棉织物底部发白的缺陷,本发明所述轧染工艺,不经打底烘干,就直接将织物液封口浸渍还原液,并经汽蒸还原上染,由此不仅大大减少了打底烘干造成的色差、泳移布面发花等疵病,而且可以降低能源消耗;其中为了避免所述湿态染料脱落较多,增大还原液还原性能,本发明中通过选择将还原糖经乙二醛溶液反应后与保险粉以及二氧化硫脲进行复配改性得到还原剂,由于还原糖经乙二醛溶液改性后,还原能力得到极大改善,其与保险粉、二氧化硫脲复配改性作为还原剂,再加入烧碱,得到了一种在低温下稳定,较高温度下还原力不断释放的还原液,因此全棉织物可以在较低温度下进行浸轧,保证还原液被均匀吸附,而当所述织物在较高温度下进行还原汽蒸时,即可以极大的改善织物的染色效果,整个布面染色均匀度、重现性且色牢度都极好,并且由于使用还原糖替代部分保险粉,可以显著降低染色排放污水中COD值,大大增强了环保性能;此后,在对织物进行氧化中,控制全棉织物氧化时的氧化温度和pH,由此获得均匀的氧化效果,再经过皂洗,去除浮色,以便保持色泽,从而可以获得较高的色牢度。
具体实施方式
实施例1
本实施例中,一种全棉织物还原染料的短湿蒸轧染工艺,包括如下工艺:
S1、浸轧染液,按浴比1:5将所述全棉织物浸轧染液,浸轧温度为40℃,轧余率为85%,所述染液的配方包括:染料25g/L、分散剂3.0g/L、渗透剂T2.0g/L;所述分散剂的配方按重量份包括:木质素磺酸钠12份、聚乙烯吡硌烷酮K-30 10份、纳米二氧化硅3份、亚硫酸钠3份、聚丙烯醇10份、平平加O 10份、水30份;
S2、加入助剂,利用高给液装置供给助剂,所述全棉织物上助剂带液率为100%,所述助剂的配方包括:还原剂5g/L、烧碱60g/L、螯合分散剂1g/L;所述还原剂的制备方法包括:将还原糖加入水中搅拌均匀,滴加乙二醛溶液,并加入磷酸钠调节pH为9-10,在60℃下搅拌反应1h,加入焦亚硫酸钠、保险粉和二氧化硫脲,在95℃下搅拌反应2h,干燥,得到所述还原剂;还原糖、乙二醛溶液、焦亚硫酸钠、保险粉和二氧化硫脲的重量配比为:1:0.1:1:0.8:0.2,所述还原糖为葡萄糖;
S3、快速汽蒸,使用饱和蒸汽进行快速汽蒸,其中,蒸箱的温度为90℃,蒸汽压力为1000Pa,蒸箱湿度为99%,汽蒸时间为2min;
S4、高温水洗,水洗温度为60℃,水洗时间5min;
S5、氧化处理,利用双氧水氧化液在温度为40℃,pH值为9-10的条件下氧化20min,接着用5℃的清水冲洗干净;所述双氧水氧化液中含有用量为0.5g/L的40wt%双氧水;
S6、皂洗,利用皂洗液在温度为98℃,pH值为10-11的条件下皂洗15min,接着用60℃的清水冲洗干净;所述皂洗液包括:净洗剂209 1g/L;纯碱2g/L。
实施例2
本实施例中,一种全棉织物还原染料的短湿蒸轧染工艺,包括如下工艺:
S1、浸轧染液,按浴比1:10将所述全棉织物浸轧染液,浸轧温度为20℃,轧余率为95%,所述染液的配方包括:染料15g/L、分散剂9.0g/L、渗透剂T1.0g/L;所述分散剂的配方按重量份包括:木质素磺酸钠18份、聚乙烯吡硌烷酮K-30 4份、纳米二氧化硅5份、亚硫酸钠1份、聚丙烯醇20份、平平加O 8份、水60份;
S2、加入助剂,利用高给液装置供给助剂,所述全棉织物上助剂带液率为90%,所述助剂的配方包括:还原剂20g/L、烧碱20g/L、螯合分散剂1.5g/L;所述还原剂的制备方法包括:将还原糖加入水中搅拌均匀,滴加乙二醛溶液,并加入磷酸钠调节pH为9-10,在40℃下搅拌反应2h,加入焦亚硫酸钠、保险粉和二氧化硫脲,在70℃下搅拌反应4h,干燥,得到所述还原剂;还原糖、乙二醛溶液、焦亚硫酸钠、保险粉和二氧化硫脲的重量配比为:1:0.01:1.5:0.6:0.4,所述还原糖为果糖;
S3、快速汽蒸,使用饱和蒸汽进行快速汽蒸,其中,蒸箱的温度为110℃,蒸汽压力为800Pa,蒸箱湿度为100%,汽蒸时间为1.5min;
S4、高温水洗,水洗温度为80℃,水洗时间3min;
S5、氧化处理,利用双氧水氧化液在温度为60℃,pH值为9-10的条件下氧化15min,接着用30℃的清水冲洗干净;所述双氧水氧化液中含有用量为3g/L的35wt%双氧水;
S6、皂洗,利用皂洗液在温度为90℃,pH值为10-11的条件下皂洗25min,接着用50℃的清水冲洗干净;所述皂洗液包括:净洗剂209 3g/L;纯碱1g/L。
实施例3
本实施例中,一种全棉织物还原染料的短湿蒸轧染工艺,包括如下工艺:
S1、浸轧染液,按浴比1:7将所述全棉织物浸轧染液,浸轧温度为30℃,轧余率为90%,所述染液的配方包括:染料20g/L、分散剂6.0g/L、渗透剂T1.5g/L;所述分散剂的配方按重量份包括:木质素磺酸钠15份、聚乙烯吡硌烷酮K-30 7份、纳米二氧化硅4份、亚硫酸钠2份、聚丙烯醇15份、平平加O 9份、水45份;
S2、加入助剂,利用高给液装置供给助剂,所述全棉织物上助剂带液率为95%,所述助剂的配方包括:还原剂12g/L、烧碱40g/L、螯合分散剂1.2g/L;所述还原剂的制备方法包括:将还原糖加入水中搅拌均匀,滴加乙二醛溶液,并加入磷酸钠调节pH为9-10,在50℃下搅拌反应1.5h,加入焦亚硫酸钠、保险粉和二氧化硫脲,在85℃下搅拌反应3h,干燥,得到所述还原剂;还原糖、乙二醛溶液、焦亚硫酸钠、保险粉和二氧化硫脲的重量配比为:1:0.05:1.2:0.7:0.3,所述还原糖为半乳糖;
S3、快速汽蒸,使用饱和蒸汽进行快速汽蒸,其中,蒸箱的温度为100℃,蒸汽压力为900Pa,蒸箱湿度为99%,汽蒸时间为1.7min;
S4、高温水洗,水洗温度为70℃,水洗时间4min;
S5、氧化处理,利用双氧水氧化液在温度为50℃,pH值为9-10的条件下氧化17min,接着用15℃的清水冲洗干净;所述双氧水氧化液中含有用量为0.2g/L的37wt%双氧水;
S6、皂洗,利用皂洗液在温度为94℃,pH值为10-11的条件下皂洗20min,接着用55℃的清水冲洗干净;所述皂洗液包括:净洗剂209 2g/L;纯碱1.5g/L。
实施例4
本实施例中,一种全棉织物还原染料的短湿蒸轧染工艺,包括如下工艺:
S1、浸轧染液,按浴比1:8将所述全棉织物浸轧染液,浸轧温度为25℃,轧余率为90%,所述染液的配方包括:染料16g/L、分散剂5.0g/L、渗透剂T1.3g/L;所述分散剂的配方按重量份包括:木质素磺酸钠16份、聚乙烯吡硌烷酮K-30 8份、纳米二氧化硅4份、亚硫酸钠2份、聚丙烯醇16份、平平加O 9份、水50份;
S2、加入助剂,利用高给液装置供给助剂,所述全棉织物上助剂带液率为98%,所述助剂的配方包括:还原剂13g/L、烧碱30g/L、螯合分散剂1.3g/L;所述还原剂的制备方法包括:将还原糖加入水中搅拌均匀,滴加乙二醛溶液,并加入磷酸钠调节pH为9-10,在45℃下搅拌反应1.6h,加入焦亚硫酸钠、保险粉和二氧化硫脲,在85℃下搅拌反应3h,干燥,得到所述还原剂;还原糖、乙二醛溶液、焦亚硫酸钠、保险粉和二氧化硫脲的重量配比为:1:0.04:1.2:0.7:0.3,所述还原糖为乳糖和麦芽糖的混合物;
S3、快速汽蒸,使用饱和蒸汽进行快速汽蒸,其中,蒸箱的温度为105℃,蒸汽压力为850Pa,蒸箱湿度为100%,汽蒸时间为1.6min;
S4、高温水洗,水洗温度为75℃,水洗时间4min;
S5、氧化处理,利用双氧水氧化液在温度为55℃,pH值为9-10的条件下氧化18min,接着用15℃的清水冲洗干净;所述双氧水氧化液中含有用量为1.6g/L的36wt%双氧水;
S6、皂洗,利用皂洗液在温度为93℃,pH值为10-11的条件下皂洗20min,接着用54℃的清水冲洗干净;所述皂洗液包括:净洗剂209 2g/L;纯碱1.2g/L。
本发明中的各项指标的测试方法如下:
(1)使用Hunter3Lab测色仪对染色下全棉织物前后色差△E进行检测;
(2)色牢度
耐皂洗色牢度按照GB/T 3921-2008《纺织品色牢度试验耐皂洗色牢度》方法D(4)测定。
耐汗渍色牢度按照GB/T 3922-1995《纺织品耐汗渍色牢度试验方法》测定。
耐摩擦色牢度按照GB/T 3920-2008《织品色牢度试验耐摩擦色牢度》测定。
耐人造光色牢度按照GB/T 8426-1998《织品色牢度试验耐光色牢度:日光》氙灯方法2测定。
上述实施例1-4得到的全棉织物的染色性能测试结果如下表所示:
本发明中,所述全棉织物还原染料的短湿蒸轧染工艺,其针对所述全棉织物的表面性能,提出了一种利用还原染料进行短湿蒸轧染工艺,所述工艺主要分为,染料还原、染料上染、染料氧化、皂洗四个阶段,首先,本发明中利用还原染料加上分散剂等形成有利于织物浸轧的染液,所述分散剂通过特定种类的表面活性剂和各种助剂复配形成,可以在染液中与染料形成染料微悬浮体,该微悬浮体聚集程度均一,且与棉纤维之间作用力增大,即可在染色低温区域对面纤维快速均匀吸附,因此不仅大大缩短了还原染料的研磨时间,而且由此形成的微悬浮体可在染浴中循环并均匀吸附和沉积在纤维上,并可向纤维内部进行扩散;此后,本发明中所述短湿蒸轧染工艺,为了避免采用“常规还原染料悬浮体轧染”方式进行全棉织物染色,在打底烘燥过程中,由于染料向毛圈上部泳移,致使棉麻织物底部发白的缺陷,本发明所述轧染工艺,不经打底烘干,就直接将织物液封口浸渍还原液,并经汽蒸还原上染,由此不仅大大减少了打底烘干造成的色差、泳移布面发花等疵病,而且可以降低能源消耗;其中为了避免所述湿态染料脱落较多,增大还原液还原性能,本发明中通过选择将还原糖经乙二醛溶液反应后与保险粉以及二氧化硫脲进行复配改性得到还原剂,由于还原糖经乙二醛溶液改性后,还原能力得到极大改善,其与保险粉、二氧化硫脲复配作为还原剂,再加入烧碱,得到了一种在低温下稳定,较高温度下还原力不断释放的还原液,因此全棉织物可以在较低温度下进行浸轧,保证还原液被均匀吸附,而当所述织物在较高温度下进行还原汽蒸时,即可以极大的改善织物的染色效果,整个布面染色均匀度、重现性且色牢度都极好,并且由于使用还原糖替代部分保险粉,可以显著降低染色排放污水中COD值,大大增强了环保性能;此后,在对织物进行氧化中,控制全棉织物氧化时的氧化温度和pH,由此获得均匀的氧化效果,再经过皂洗,去除浮色,以便保持色泽,从而可以获得较高的色牢度。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (8)
1.一种全棉织物还原染料的短湿蒸轧染工艺,其特征在于,包括如下工艺:
S1、浸轧染液,按浴比1:5-10将所述全棉织物浸轧染液,浸轧温度为20-40℃,轧余率为85-95%,所述染液的配方包括:染料15-25g/L、分散剂 3.0-9.0g/L、渗透剂T 1.0-2.0g/L;
S2、加入助剂,利用高给液装置供给助剂,所述全棉织物上助剂带液率为90-100%,所述助剂的配方包括:还原剂5-20g/L、烧碱20-60g/L、螯合分散剂1-1.5g/L;
S3、快速汽蒸,使用饱和蒸汽进行快速汽蒸,其中,蒸箱的温度为90-110℃,蒸箱湿度为99-100%,汽蒸时间为1.5-2min;
S4、高温水洗,水洗温度为60-80℃,水洗时间3-5min;
S5、氧化处理,利用双氧水氧化液在温度为40-60℃,pH值为9-10的条件下氧化15-20min,接着用5-30℃的清水冲洗干净;
S6、皂洗,利用皂洗液在温度为90-98℃,pH值为10-11的条件下皂洗15-25min,接着用50-60℃的清水冲洗干净;
在S1中,所述分散剂的配方按重量份包括:木质素磺酸钠12-18份、聚乙烯吡硌烷酮K-30 4-10份、纳米二氧化硅3-5份、亚硫酸钠1-3份、聚丙烯醇10-20份、平平加O 8-10份、水30-60份;
所述还原剂的制备方法包括:将还原糖加入水中搅拌均匀,滴加乙二醛溶液,并加入磷酸钠调节pH为9-10,在40-60℃下搅拌反应1-2h,加入焦亚硫酸钠、保险粉和二氧化硫脲,在70-95℃下搅拌反应2-4h,干燥,得到所述还原剂;其中,还原糖、乙二醛溶液、焦亚硫酸钠、保险粉和二氧化硫脲的重量配比为:1:0.01-0.1:1-1.5:0.6-0.8:0.2-0.4。
2.根据权利要求1所述的全棉织物还原染料的短湿蒸轧染工艺,其特征在于,所述分散剂的制备工艺包括,按配比将各组分混合,搅拌均匀后得到所述分散剂。
3.根据权利要求1所述的全棉织物还原染料的短湿蒸轧染工艺,其特征在于,所述还原糖为葡萄糖、果糖、半乳糖、乳糖和麦芽糖中的至少一种。
4.根据权利要求1-3任一项所述的全棉织物还原染料的短湿蒸轧染工艺,其特征在于,在S3中,蒸汽压力为800-1000Pa。
5.根据权利要求4所述的全棉织物还原染料的短湿蒸轧染工艺,其特征在于,在S5中,所述双氧水氧化液中含有用量为0.5-3g/L的35-40wt%双氧水。
6. 根据权利要求4所述的全棉织物还原染料的短湿蒸轧染工艺,其特征在于,在S6中,所述皂洗液包括:净洗剂209 1-3g/L;纯碱1-2g/L。
7.根据权利要求5所述的全棉织物还原染料的短湿蒸轧染工艺,其特征在于,在S6中,所述皂洗液包括:净洗剂209 1-3g/L;纯碱1-2g/L。
8.根据权利要求6所述的全棉织物还原染料的短湿蒸轧染工艺,其特征在于,皂洗工艺后,还包括烘干,烘干温度为80-100℃,烘干时间为5-10min。
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