With the continuous development of industry and technology, various synthetic fiber fabrics have emerged one after another. Polar fleece is a type of polyester fiber knitted fabric. It is woven on a circular knitting machine. After being woven, the gray fabric is first pre-treated, dyed, and then processed through various complex finishing processes such as napping, carding, shearing, and polarization. Processing, the front side of the fabric is brushed, the polar fleece is fluffy and dense but not easy to shed or pill, the back side is brushed sparsely and evenly, the fluff is short, the texture is clear, and the fluffy elasticity is very good. Its ingredients are generally 100% polyester and it feels soft, making it a good product to keep out the cold in winter. Polar fleece can also be combined with other fibers to make it more effective in keeping out the cold. The fabric composition is generally polyester. Because polyester fiber has low hygroscopicity and high crystallinity, it is easy to generate static electricity; it is lipophilic and easy to stain, so it needs anti-static and anti-fouling treatment. By screening additives with good compatibility and different performance types, and strictly controlling temperature, time, and pH value to achieve better performance, in order to meet market demand, low-cost and high-efficiency process technology must be developed. Based on our theoretical knowledge combined with practical experience in the factory, we learn from the functions of additive companies to develop new products. The design process is more energy-saving and emission-reducing
Traditional process flow: blank inspection – pre-treatment – dyeing – soft pre-shaping – finishing – drying – brushing – carding – shearing – high temperature steaming and shaking (finishing) – finished product inspection
The improved process is mainly reflected in the finishing of waterproof, anti-fouling, oil-proof effects and anti-flame retardant effects. By screening additives with good compatibility and different performance types, and strict control of temperature, time and PH value Control to achieve better three-defense effect.
In order to remove the oil and antistatic agent applied to the fiber during spinning and the oil stains during weaving. Through pre-treatment and bleaching, on the one hand, the excellent quality of the fiber can be fully utilized, and more importantly, it can meet the requirements of fabric whiteness, moisture absorption and permeability for a series of subsequent processing such as post-finishing. The purpose of adding penetrant is to increase the permeability of the fabric to avoid adverse effects on the dyeing and finishing effects.
Process prescription:
Caustic soda 2-3 g/L
ZJ-C02 1.5 g/L
ZJ-302 2 g/L
Process conditions
Heating rate: 2.5℃/min
Refining temperature: 100℃
Keeping time: 45min
Liquor ratio: 1:10
After refining, the surface of the fabric is concave, which reduces the smoothness of the fiber surface and improves the hydrophilicity of the fabric.
Chelating dispersant ZJ-C02 is anionic, has excellent acid resistance, oxidation resistance, reduction resistance, and good stability and dispersion. It can chelate calcium, magnesium, and iron ions in the water, thus softening the water. It has a very good promotion effect on subsequent dyeing and finishing processing.
Dyeing after refining
Dyeing process: cloth feeding→dyeing→reduction cleaning→hot water washing→cold water washing→out of the vat
Problems and solutions in the dyeing process
Defect name prevention methods
Reduce the dyeing rate and reduce the color change 1. Control the appropriate pH value
2． Choose pH-insensitive dyes
3. Dye vat inspection
4. Choose dyes with better color stability
Chicken paw prints and wrinkles 1. Styling before dyeing and strengthening pre-treatment
2． Increase the liquor ratio and reduce the loading capacity
3． Cool down slowly
4. Adjust the nozzle
5. Add appropriate amount of anti-wrinkle agent ZJ-R04 in the bath
Fuzziness on the fabric surface, poor level dyeing, stripes, and dye spots 1. Strictly control the process
2． Choose good dyes and auxiliaries
3． Strengthen desizing and cleaning
4. Improve spray power, control liquid volume, and strengthen dye liquor circulation
5. Clean the cylinder before dyeing to prevent the production of oligomers
The fabric fastness is poor 1. Choose dyes with better fastness
2． Use dyes with better dye synchronization
3． Strengthen the reduction cleaning after dyeing, or choose a second time.
Soft and pre-shaped
Prescription (g/L)
ZJ-Z02 fluffing agent 40-60
ZJ-G17 Softener 10-40
One dip and one rolling at room temperature
Vehicle speed (m/min) 25-30
Setting temperature (℃) 170-180
Raising – combing – shearing
Raising uses the force of mechanical front and back friction to make the medium and long fibers of the fabric stand up as much as possible, turning the excess hair of the medium and long fibers into fluff of different lengths.
Combing also uses the mechanical force of the machine to straighten the surface of the fabric and comb the hair in the same direction to make the hair on the surface of the fabric consistent.
Shearing uses mechanical force to remove excess fluff on the surface of the fabric, making the cloth surface smooth, uniform in length and velvety
Shake grain
Put the sheared gray fabric into a vertical roller machine and steam it with high temperature and high pressure to steam the fluff into granular form, that is, shaken particles
Process conditions and precautions
When the temperature of the shaken particles is not lower than the required temperature, the high temperature should be maintained for ten minutes, and the rotation speed should be 10rad. It can only be taken out when it drops to normal temperature, otherwise wrinkles will easily appear.
Three-proof and flame-retardant finishing
Auxiliary selection
The compatibility between additives must be taken into consideration. The TEXCOTE, antistatic agent, and flame retardant FR-4 used below have good compatibility.
Working fluid formula (g/L)
TEXCOTE 40-60
Antistatic agent FCH001 40-80
Flame retardant FCE003 140-160
Heating and shaping process after sizing: Vehicle speed 12-18m/min;
Setting temperature: 170-190℃
Among them, TEXCOTE is manufactured by Swedish Decon Nano.��Antistatic agent and flame retardant FCE003 are provided by. This product has been tested by a nationally recognized testing agency and shows:
Water repellent, oil repellent, stain repellent mechanism
After the fabric is water- and oil-repellent, the surface free energy is reduced, which increases the contact angle of liquid on its surface and prevents liquid dirt from spontaneously being sucked into the yarn, which requires higher pressure to enter. Make fabrics resistant to liquid stains
Application of anti-oil finishing agent: Polyester is lipophilic, so it is easy to stain. Oil stains are difficult to remove during washing and may be stained again. Therefore, anti-oil treatment is needed. In addition to making the fabric less susceptible to stains, anti-oil finishing agents mainly rely on improving the hydrophilicity and antistatic properties of the fabric. The mechanism is similar to antistatic.
Effect of pH value
The ionic properties of polyester fiber in the bath solution: weak anionic properties, and as the pH value increases, the anionic properties become stronger. Waterproof and oilproof should be under acidic conditions so that the working fluid is relatively stable. Optimum pH range: 4-5
Effect of temperature
The setting temperature is controlled at 170-190℃. If the temperature is too low, it will be unfavorable for the penetration and cross-linking of additives, and the three-proof flame retardant effect will not be achieved. If the temperature is too high, the anti-static effect will be affected
Measures to deal with adverse outcomes
Poor waterproof performance, poor durability, occurrence of waterproof stains and streaks, large changes in color and light, etc. In response to the above problems, through many experiments, we found the causes of the problems and proposed measures.
(a) Choose a fluid suitable for processing polar fleece, and replenish the newly prepared working fluid as much as possible during processing. Strengthen the removal of surfactants before finishing. Strengthen the temperature management of the processed fabric, pay attention to the compatibility of additives, and try to use the prepared working fluid within 24 hours.
(b) Waterproof and oilproof should be under acidic conditions so that the working fluid is relatively stable.
Finished product inspection
Process flow
Inspecting cloth → folding → grading → trimming and washing → cutting and finishing → packing
Things to note: Repair and wash
After the fabric is folded and graded, some defects may have been downgraded, but repairing, weaving, and washing will not affect the quality of the fabric and require little effort. It not only reduces defects on the cloth surface, but also improves the quality of the cloth surface and increases its use value. After trimming and washing, the cloth must be neatly folded and stacked as required.
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