Polar fleece
Polar fleece fabric is soft, lightweight, quick-drying, easy to wash, and can still keep out the cold when it gets wet. Under the same conditions, it is twice as cold-resistant as merino wool and four times as cold-resistant as cotton. Lightweight polar fleece is easy to move and comfortable to wear.
The main component of polar fleece is polyester fiber (polyester). Its advantages are high strength, good elasticity, good heat resistance, good wear resistance, and sunlight resistance. Good, corrosion-resistant, light weight, good warmth retention, not afraid of enzyme damage. Another outstanding advantage is that it is easy to take care of and can be washed.
In addition, polar fleece can also be combined with any other fabric to make the cold-proof effect better (polar fleece combined with polar fleece, polar fleece combined with denim, Polar fleece and lambswool composite, polar fleece and mesh fabric composite with a waterproof and breathable membrane in the middle, etc.).
Processing Flow
Processing Flow : Fabric sorting → dyeing → adding fluffing agent to the dye vat → dehydration → drying → slitting → brushing → carding → shearing → shaking → finished product shaping → final inspection → packaging → warehousing.
Notes
1. The dyeing and finishing process and parameter design must take into account maintaining the shape of the hollow fibrils as much as possible to avoid shrinkage of the fiber cavity, otherwise it will be difficult to reflect the difference between special-shaped hollow fibers and conventional fibers.
2. When designing the process parameters of each process, ensure that the polar fleece has a thick and fluffy effect, increase the static air layer between fibers, and improve the fabric. Warmth, lightness and softness.
Production process
1. Special-shaped hollow polyester fiber fabrics are dyed using high temperature and high pressure. The dyeing temperature is generally 120~130℃. While ensuring the color fastness requirements, try to use 120℃ for dyeing. The holding time should not exceed 30 minutes to reduce the risk of high dyeing temperature and long dyeing time. The phenomenon that affects the shrinkage of fibers.
During the dyeing operation, the tank volume should not be too large. Try not to exceed 80% of the tank capacity to avoid overlapping the cloth in the dye vat for a long time.
2. The method of adding fluffing agent and fluffing agent is divided into shaping plus fluffing agent and dyeing vat plus fluffing agent.
The dye vat is soaked with raising agent at room temperature. The advantage is that when adding raising agent, the cloth body is less affected by tension and becomes relaxed, which will not change the shape of the special-shaped hollow filament. Moreover, the auxiliary agent has a long action time on the fiber. , relatively uniform and with high production efficiency, so a dye vat is used to add fluffing agent.
3. Brushing uses mechanical straight needles to flatten the cloth surface, and curved needles (needle lifts) to gradually break off the fibers on the terry loops layer by layer, and continuously hook and pull them. Loop yarn, loosen the loop yarn, form independent fluff, feather and cover the surface of the fabric.
Because the curved needle continuously hooks and pulls the loop yarn, the fabric shrinks longitudinally and transversely, the fabric body is thick, not easy to shed, the fluff is fluffy, and the added value of the fabric is increased.
When adjusting the bristle machine, attention should be paid to the tension and fluff rate (ie, the speed of the looper). The tension determines the length of the hair, and the fluff rate determines the density of the fluff.
The process parameters of special-shaped hollow polyester fiber and conventional polyester fiber polar fleece bristles are shown in the table
The faster the needle covering speed, the looser the tension, and the faster the needle starting speed. The faster, the higher the fluff rate. On the contrary, the tighter the tension, the lower the fluff rate. The gaps between the pre-shaped special-shaped hollow polyester fibers are large, and the tension during brushing is looser than that of conventional polar fleece, and the bristles can be brushed lightly. The bristle card clothing uses curved needle bristles with low density and good elasticity to easily hook and feather the hollow fibers, reducing the chance of elongating and breaking the hollow fibers and reducing losses.
4. The semi-finished product after combing is passed through the needle roller of the combing machine to straighten the messy hair, stand upright, comb out the broken hair in the fluff, and let the combed hair The hair becomes fluffy and straight after shearing, making the hair uniform in length after shearing and making it easier to grain.
Carding process parameters of special-shaped hollow polyester fiber and conventional polyester fiber polar fleece.
The tension adjustment in sections A, B, and C is to stick the fabric flatly on the carding machine plate to ensure uniform combing. The tension is generally only fine-tuned. The combing rate is the main factor in combing adjustment. The higher the combing rate, the heavier the combing, and vice versa.
The gaps between special-shaped hollow polyester fibers are large, and light combing can meet the requirements. It can reduce the degree of stretching and breaking of the hollow fibers, and the hollow fibers can be straightened and fluffed.
5. After shearing, the pile fibers on the surface of plush fabrics are of different lengths after weaving, untwisting or brushing, and the pile needs to be cut into upright, neat short hairs; Or cut the long hair neatly to make the pile surface flat. The length of the sheared hair directly determines the size of the particles. The longer the hair, the larger the particles, and the fluffier the particle style. The more static air content in the special-shaped hollow polyester fiber, the better the warmth retention.
Therefore, to produce ultra-fluffy special-shaped hollow polyester fiber polar fleece, the hair left after shearing should be longer, and less floating hair will be cut off, thus reducing shearing loss. However, the hair left after shearing should not be too long, otherwise there will be too much floating hair on the cloth surface and the rough surface will be uneven, which will make the particles formed after shaking and not smooth, affecting the beauty.
When shearing, adjust the angles of the triangular knife and the circular knife according to the thickness of the cloth, so that the cut fluff is upright and not lodging, so that the fluff has free space to intertwine and shrink with each other during the shaking, forming full and fluffy particles, otherwise the hair will form. The particles are relatively flat and not fluffy.
6. Shake pellet: The cloth is mechanically turned and blown by hot air in the shake pellet machine, so that the fluff and fluff are entangled, pelletized and shrunk with each other. There are currently two types of shaker machines: tension-free shaker barrels and jet-type continuous shaker machines.
The tension-free shaker bucket is a traditional shaker method. After shearing, the cloth head must be cut, and the shaker must be held and pulled manually, which is high loss and labor-intensive. The tension-free shaker barrel relies on steam heating, hot air drying and cold air cooling.
The jet-flow continuous shaker anti-shrinking machine uses hot air for heating and cold air for cooling. After shearing, there is no need to cut the cloth end. The cloth is directly fed into the jet-type continuous shaker and shrink-proof machine through the cloth guide wheel. The cloth rotates in the shaker, and the hot air blows, oscillates, and rubs to form particles.
The polar fleece barrel uses direct steam to heat the polar fleece. The temperature cannot be set according to the process requirements. High temperature will cause the special-shaped hollow polyester fibers to shrink greatly, reduce the hollow volume, and affect the hollow structure and fluffiness of the polar fleece. Spend. Hollow fibers are suitable for production using a temperature-adjustable jet-flow continuous shaker anti-shrinking machine.
7. When shaping the finished special-shaped hollow polyester fiber, the tensile tension should be small to reduce the narrow and long hollow pipes caused by the stretching of the special-shaped hollow fiber. , the probability of hollow wall adhesion, and avoid the occurrence of linting due to excessive stretching, thereby reducing the fluffiness of the shaken style. The finished product of the polarized cloth should not be shaped by rollers, otherwise it will affect the fluffy feeling of the polarized cloth. </p
