CN114635245B - 一种提升涤纶织物染色品质的快速高效前处理工艺 - Google Patents

一种提升涤纶织物染色品质的快速高效前处理工艺 Download PDF

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CN114635245B
CN114635245B CN202210221483.2A CN202210221483A CN114635245B CN 114635245 B CN114635245 B CN 114635245B CN 202210221483 A CN202210221483 A CN 202210221483A CN 114635245 B CN114635245 B CN 114635245B
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王宗乾
郑嫚嫚
王鹏
盛红梅
杨海伟
钟辉
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Anhui Polytechnic University
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Abstract

本发明公开了一种提升涤纶织物染色品质的快速高效前处理工艺，包括坯布含水量检测工序、匀质工序、高效三浸三轧前处理工序、漂洗工序，解决了传统坯布前处理工艺设备占地长、投入成本大、耗水量多的问题；确保涤纶坯布的布面带水量的一致性和均匀性，提高了坯布前处理的均匀度和综合品质；保证坯布表面多余的工作液以及被坯布暂时携带的游离工作液在压力作用下回流到工作液槽中，提高化学药剂的利用率，降低了成本；确保漂洗后布面的洁净度。

Description

一种提升涤纶织物染色品质的快速高效前处理工艺
技术领域
本发明属于纺织技术领域，具体地说，本发明涉及一种提升涤纶织物染色品质的快速高效前处理工艺。
背景技术
常规的纺织品染整加工前处理工艺流程长，包括了退浆、精炼、漂白、丝光(对棉纤维)或碱减量(对涤纶纤维)、增白等工序。最后还需要采用长环漂洗工艺进行处理，这其中含有四至七格水洗。整个前处理工艺流程设备的缺点：占地长，投入成本大，耗水量多。整个前处理工艺流程各工序之间还有烘干步骤，属于高耗能加工。纺织品前处理工艺流程的耗水量多、耗能量大，约占整个染整加工前处理工艺流程的45-55％的能耗。按照“双碳”目标要求，开发纺织品坯布短流程快速高效前处理工艺，实现流程再造势在必行，也具有极其重要的现实意义。
涤纶以及含涤纺织品的前处理加工更为突出。经喷水织造工艺生产的涤纶纺织品布面带有一定的水分，粘附在涤纶坯布表面的水分中含有大量的抗静电剂、油剂、浆料等化学品，这些杂质均需要在前处理工序中去除。传统加工是将上述涤纶坯布进行烘干处理，再统一进行后续的印染加工，这势必造成大量的能耗。若直接将该涤纶坯布直接转运到印染加工车间，也会带来其他的问题，一方面涤纶坯布表面含水量不均匀，不一致；另外一方面涤纶坯布在转运过程中，会造成装布车上层的涤纶坯布水分挥发，含水量小，下层涤纶坯布由于重力作用含水量多。
实践证明若直接将该涤纶坯布进行浸轧前处理工艺处理，势必造成前处理品质的均匀性差，影响后续的染色和印花加工，易形成色花。为解决上述问题，迫切需要研制一种涤纶坯布快速高效前处理技术，实现染整加工品质和节能降耗的双提升。
发明内容
本发明提供一种提升涤纶织物染色品质的快速高效前处理工艺，以解决上述背景技术中存在的问题。
为了实现上述目的，本发明采取的技术方案为：一种提升涤纶织物染色品质的快速高效前处理工艺，具体包括坯布含水量检测工序、匀质工序、高效三浸三轧前处理工序、漂洗工序，
步骤S1：坯布含水量检测工序，坯布从常规导布辊一上端输入，常规导布辊一上端设置的湿度传感器与喷淋头检测并控制涤纶坯布的含水量，由湿度传感器检测常规导布辊一上的坯布的表面湿度，喷淋头根据湿度传感器检测到含水量不足的坯布部位进行喷淋，从而使织物含水量一致；
步骤S2：匀质工序，面含水量一致的涤纶坯布经浸轧棍组合装置一后，可进一步均匀坯布的含水量，然后通过常规导布辊二进入前处理槽，进入下一步操作；
步骤S3：高效三浸三轧前处理工序，坯布在前处理槽中，依次交替经过浸轧棍组合装置二、回流/高效浸轧棍组合装置的三浸三轧处理，完成织物中多余工作液回流，达到织物去油增白的效果，使坯布的前处理更加彻底、高效；
步骤S4：漂洗工序，通过高效前处理的涤纶织物进入漂洗槽漂洗，在漂洗槽中的浸轧棍组合装置二、回流/高效浸轧棍组合装置作用下除去织物表面的漂洗液；
步骤S5：漂洗后的涤纶织物即可完成前处理全部工艺，可直接进行后续的染色，实现连续式短流程涤纶前处理。
优选的，所述步骤S1中的坯布含水量检测工序是基于微波透射方法测试布面的含水量。
优选的，所述步骤S2中的浸轧棍组合装置一上下对称设置，所述步骤S3和S4中的浸轧棍组合装置二上下对称设置，所述步骤S3和S4中的回流/高效浸轧棍组合装置包括承压棍和施压棍，且施压棍在承压棍的左上方60°的方向。
优选的，所述步骤S4中的漂洗工序，通过在线检测水质的电导率，进行自动排水并增补新鲜水，确保漂洗后布面的洁净度。
优选的，所述步骤S4中的漂洗工序，漂洗液的电导率阈值设为7500μS/cm。
优选的，所述步骤S3中的高效三浸三轧前处理工序的前处理工作液组成如下，
优选的，所述高耐碱湿布丝光渗透剂主要成为丙烯酸-植酸系多元共聚物；将75％丙烯酰胺、12％N-乙基吡咯烷酮、3％植酸混合，滴加氧化锌分散液，并匀质；加入过硫酸盐引发剂，在80℃下聚合反应40min，最后进行碱中和。
优选的，所述步骤S4中的漂洗工作液组成如下，
酒石酸 0.85g/L；
TF-129K去油剂 0.1g/L；
高效皂洗防沾污剂 1.5g/L。
采用以上技术方案的有益效果是：
1、本发明的提升涤纶织物染色品质的快速高效前处理工艺，具体包括坯布含水量检测工序、匀质工序、高效三浸三轧前处理工序、漂洗工序，构建的生产线整体长度在1.4m，解决了传统坯布前处理工艺设备占地长、投入成本大、耗水量多的问题。
2、所述步骤S1坯布含水量检测工序和所述步骤S2匀质工序，通过湿度传感器进行在线监控，自动调整喷淋头喷水量，确保涤纶坯布的布面带水量的一致性和均匀性，提高了坯布前处理的均匀度和综合品质。所述步骤S1中的坯布含水量检测工序是基于微波透射方法测试布面的含水量，具有高效率、高精度的特点。
3、所述步骤S3高效三浸三轧前处理工序和所述步骤S4漂洗工序中的浸轧棍组合装置二保证了涤纶坯布与前处理工作液和漂洗工作液的充分接触；高效三浸三轧前处理工序和漂洗工序中的回流/高效浸轧棍组合装置包括承压棍和施压棍，且施压棍在承压棍的左上方60°的方向，保证坯布表面多余的工作液以及被坯布暂时携带的游离工作液在压力作用下回流到工作液槽中，提高化学药剂的利用率，降低了成本。
4、所述步骤S4中的漂洗工序，通过在线检测水质的电导率，当漂洗工作液的电导率值高于7500μS/cm时，将自动开启排水阀门和自动进水阀门，进行自动排水并增补新鲜水，确保漂洗后布面的洁净度。
附图说明
图1是本发明的提升涤纶织物染色品质的快速高效前处理工艺流程图；
图2是平纹坯布前处理前的静态接触角；
图3是平纹坯布前处理后的静态接触角；
图4是平纹坯布前处理前的毛效图；
图5是平纹坯布前处理后的毛效图；
图6是缎纹坯布前处理前的静态接触角；
图7是缎纹坯布前处理后的静态接触角；
图8是不同前处理工艺处理涤纶坯布的染色指标；
其中：
1、湿度传感器；2、常规导布辊一；3、喷淋头；4、浸轧棍组合装置一；5、常规导布辊二；6、浸轧棍组合装置二；7、回流/高效浸轧棍组合装置；14、前处理槽；15、漂洗槽。
具体实施方式
下面对照附图，通过对实施例的描述，对本发明的具体实施方式作进一步详细的说明，目的是帮助本领域的技术人员对本发明的构思、技术方案有更完整、准确和深入的理解，并有助于其实施。
如图1至图8所示，本发明是一种提升涤纶织物染色品质的快速高效前处理工艺，解决了传统坯布前处理工艺设备占地长、投入成本大、耗水量多的问题；确保涤纶坯布的布面带水量的一致性和均匀性，提高了坯布前处理的均匀度和综合品质；保证坯布表面多余的工作液以及被坯布暂时携带的游离工作液在压力作用下回流到工作液槽中，提高化学药剂的利用率，降低了成本；确保漂洗后布面的洁净度。
具体的说，如图1至图8所示，一种提升涤纶织物染色品质的快速高效前处理工艺，具体包括坯布含水量检测工序、匀质工序、高效三浸三轧前处理工序、漂洗工序，
步骤S1：坯布含水量检测工序，坯布从常规导布辊一2上端输入，常规导布辊一2上端设置的湿度传感器1与喷淋头3检测并控制涤纶坯布的含水量，由湿度传感器1检测常规导布辊一2上的坯布的表面湿度，喷淋头3根据湿度传感器1检测到含水量不足的坯布部位进行喷淋，从而使织物含水量一致；
步骤S2：匀质工序，面含水量一致的涤纶坯布经浸轧棍组合装置一4后，可进一步均匀坯布的含水量，然后通过常规导布辊二5进入前处理槽14，进入下一步操作；
步骤S3：高效三浸三轧前处理工序，坯布在前处理槽14中，依次交替经过浸轧棍组合装置二6、回流/高效浸轧棍组合装置7的三浸三轧处理，完成织物中多余工作液回流，达到织物去油增白的效果，使坯布的前处理更加彻底、高效；
步骤S4：漂洗工序，通过高效前处理的涤纶织物进入漂洗槽15漂洗，在漂洗槽15中的浸轧棍组合装置二6、回流/高效浸轧棍组合装置7作用下除去织物表面的漂洗液；
步骤S5：漂洗后的涤纶织物即可完成前处理全部工艺，可直接进行后续的染色，实现连续式短流程涤纶前处理。
所述步骤S1中的坯布含水量检测工序是基于微波透射方法测试布面的含水量。
所述步骤S2中的浸轧棍组合装置一4上下对称设置，所述步骤S3和S4中的浸轧棍组合装置二6上下对称设置，所述步骤S3和S4中的回流/高效浸轧棍组合装置7包括承压棍和施压棍，且施压棍在承压棍的左上方60°的方向。
所述步骤S4中的漂洗工序，通过在线检测水质的电导率，进行自动排水并增补新鲜水，确保漂洗后布面的洁净度。
所述步骤S4中的漂洗工序，漂洗液的电导率阈值设为7500μS/cm。
所述步骤S3中的高效三浸三轧前处理工序的前处理工作液组成如下，
所述高耐碱湿布丝光渗透剂主要成为丙烯酸-植酸系多元共聚物；将75％丙烯酰胺、12％N-乙基吡咯烷酮、3％植酸混合，滴加氧化锌分散液，并匀质；加入过硫酸盐引发剂，在80℃下聚合反应40min，最后进行碱中和。
所述步骤S4中的漂洗工作液组成如下，
酒石酸 0.85g/L；
TF-129K去油剂 0.1g/L；
高效皂洗防沾污剂 1.5g/L。
以下用具体实施例对具体工作方式进行阐述：
实施例1：
经本发明的提升涤纶织物染色品质的快速高效前处理工艺加工的涤纶坯布(平纹，克重为90g/m2),如图2、图3所示，未处理坯布的静态接触角为113.9°，前处理后的静态接触角变为了33.3°。静态接触角越小，表明表面亲水性提升，前处理取得了理想的结果。
对比测试处理前后织物的毛效(芯吸)效果，结果如图4、图5所示，基于本发明的提升涤纶织物染色品质的快速高效前处理工艺处理织物的5min毛效达到6.35cm，未处理的坯布毛效仅为3.25cm，吸收性能大大提升。
实施例2：
经本发明的提升涤纶织物染色品质的快速高效前处理工艺加工的涤纶坯布(缎纹，克重为65g/m2),如图6、图7所示，未处理坯布的静态接触为在73.3°，前处理处理后的静态接触角变为了28.3°。
实施例3：
为表明本发明的提升涤纶织物染色品质的快速高效前处理工艺加工涤纶坯布的均匀性指标，选取了4块前处理后的坯布进行染色，以常规前处理工艺处理的坯布织物为标准样，进行对比分析，结果如图8所示。
经对比分析，与常规前处理工艺加工的坯布进行对比，本发明的提升涤纶织物染色品质的快速高效前处理工艺加工坯布的前处理均匀性非常理想，4次测试综合色差均小于0.5，属于极微小的色差，同时颜色的色泽也无影响。
以上结合附图对本发明进行了示例性描述，显然，本发明具体实现并不受上述方式的限制，只要是采用了本发明的方法构思和技术方案进行的各种非实质性的改进；或未经改进，将本发明的上述构思和技术方案直接应用于其它场合的，均在本发明的保护范围之内。

Claims (4)

1.一种提升涤纶织物染色品质的快速高效前处理工艺，其特征在于：具体包括坯布含水量检测工序、匀质工序、高效三浸三轧前处理工序、漂洗工序，
步骤S1：坯布含水量检测工序，坯布从常规导布辊一(2)上端输入，常规导布辊一(2)上端设置的湿度传感器(1)与喷淋头(3)检测并控制涤纶坯布的含水量，由湿度传感器(1)检测常规导布辊一(2)上的坯布的表面湿度，喷淋头(3)根据湿度传感器(1)检测到含水量不足的坯布部位进行喷淋，从而使织物含水量一致；
步骤S2：匀质工序，面含水量一致的涤纶坯布经浸轧棍组合装置一(4)后，可进一步均匀坯布的含水量，然后通过常规导布辊二(5)进入前处理槽(14)，进入下一步操作；
步骤S3：高效三浸三轧前处理工序，坯布在前处理槽(14)中，依次交替经过浸轧棍组合装置二(6)、回流/高效浸轧棍组合装置(7)的三浸三轧处理，完成织物中多余工作液回流，达到织物去油增白的效果，使坯布的前处理更加彻底、高效；
步骤S4：漂洗工序，通过高效前处理的涤纶织物进入漂洗槽(15)漂洗，在漂洗槽(15)中的浸轧棍组合装置二(6)、回流/高效浸轧棍组合装置(7)作用下除去织物表面的漂洗液；
步骤S5：漂洗后的涤纶织物即可完成前处理全部工艺，可直接进行后续的染色，实现连续式短流程涤纶前处理；
所述步骤S2中的浸轧棍组合装置一(4)上下对称设置，所述步骤S3和S4中的浸轧棍组合装置二(6)上下对称设置，所述步骤S3和S4中的回流/高效浸轧棍组合装置(7)包括承压棍和施压棍，且施压棍在承压棍的左上方60°的方向；
所述步骤S3中的高效三浸三轧前处理工序的前处理工作液组成如下，
所述高耐碱湿布丝光渗透剂主要成为丙烯酸-植酸系多元共聚物；将75％丙烯酰胺、12％N-乙基吡咯烷酮、3％植酸混合，滴加氧化锌分散液，并匀质；加入过硫酸盐引发剂，在80℃下聚合反应40min，最后进行碱中和；
所述步骤S4中的漂洗工作液组成如下，
酒石酸0.85g/L；
TF-129K去油剂0.1g/L；
高效皂洗防沾污剂1.5g/L。
2.根据权利要求1所述的一种提升涤纶织物染色品质的快速高效前处理工艺，其特征在于：所述步骤S1中的坯布含水量检测工序是基于微波透射方法测试布面的含水量。
3.根据权利要求1所述的一种提升涤纶织物染色品质的快速高效前处理工艺，其特征在于：所述步骤S4中的漂洗工序，通过在线检测水质的电导率，进行自动排水并增补新鲜水，确保漂洗后布面的洁净度。
4.根据权利要求1所述的一种提升涤纶织物染色品质的快速高效前处理工艺，其特征在于：所述步骤S4中的漂洗工序，漂洗液的电导率阈值设为7500μS/cm。
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