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. Dyeing
Special-shaped hollow polyester fiber fabrics are dyed with high temperature and high pressure. The dyeing temperature is generally 120~130℃. While ensuring the color fastness requirements, try to use 120℃ dyeing and heat preservation. The time should not exceed 30 minutes to reduce the shrinkage of fibers caused by high dyeing temperature and long dyeing time. During the dyeing operation, the tank volume should not be too large, and try not to exceed 80% of the tank capacity to avoid overlapping the cloth in the dye vat for a long time.
2. Adding fluffing agent
The methods of adding fluffing agent are divided into Add fluffing agent to the shape setting and fluffing agent to the dye vat. Adding fluffing agent to the dye vat requires impregnating the fluffing agent at normal temperature. The advantage is that when adding fluffing agent, the cloth body is less affected by tension and is relaxed, which will not change the shape of the special-shaped hollow filament. Moreover, the auxiliary agent acts on the fiber for a long time, is relatively uniform, and has high production efficiency. , so a dye vat is used to add fluffing agent.
3. Bristles
Bristles It uses mechanical straight needles to flatten the fabric surface, and curved needles (needle lifters) to gradually break off the fibers on the loops layer by layer, and continuously hook and pull the loop yarns to loosen the loop yarns, forming independent fluff, feathering and covering the fabric. surface.
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, the faster the needle lifting speed, 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. Combing
Brushing The final semi-finished product passes through the needle roller of the carding machine to comb out and straighten the messy hair, stand the down hair, and comb out the broken hair in the fluff, so that the fluff becomes fluffy and straight after combing, so that the hair length after shearing is consistent, and the hair is shaken. Easy to form grains. Carding process parameters of special-shaped hollow polyester fiber and conventional polyester fiber polar fleece.
The adjustment of the tension in sections A, B, and C is to stick the fabric flatly on the carding machine plate to ensure even 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 elongation and breakage of the hollow fibers, and just straighten and fluff the hollow fibers.
5. Shearing
Fleece After being woven, untwisted or brushed, the pile fibers on the surface of the fabric are of different lengths. The pile needs to be cut short into upright, neat short hair; or the long hair should be cut to make the pile surface flat. The length of 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, when producing 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 the surface of the cloth will become loose.If too much, the rough surface will be uneven, which will make the particles formed after shaking into blurry and not smooth, affecting the aesthetics.
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 with each other during shaking. , shrink to form full, fluffy particles, otherwise the resulting particles will be flat and not fluffy.
6. Shake grains
The fluff is made of cloth that is mechanically turned and blown by hot air in a fletching machine, so that the fluff and fluff are entangled with each other, grained, and shrunk. There are currently two types of shaker machines: tension-free shaker barrels and jet-type continuous shaker machines.
The tension-free shaker barrel is a traditional shaker method. After shearing, the cloth head needs to be cut, and the shaker relies entirely on manual holding and pulling of the cloth, 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-type 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 Hollow structure and fluffiness. Hollow fibers are suitable for production using a temperature-adjustable jet-flow continuous shaker anti-shrinking machine.
7. Finished product shaping
When shaping the special-shaped hollow polyester fiber, the stretching tension should be small to reduce the probability of the special-shaped hollow fiber making the hollow pipe narrow and long and the hollow wall adhering due to stretching, and to avoid linting due to excessive stretching. And reduce the fluffiness of 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
