活性染料拼色轧染过程中补液模型的研究

doi:10.13475/j.fzxb.20220100706

摘要/Abstract

摘要：

为探究染料拼色轧染体系中补液系统的数字化控制方法,基于拉曼光谱技术对染料拼色染色过程进行实时监测,建立了染料拼色轧染过程中的补液模型。利用拉曼光谱技术与偏最小二乘法(PLS)相结合的方法,建立拼色染料浓度的定量分析模型,实现染料拼色上染过程的实时监测,得到染料拼色上染过程中各染料的初始上染速率值;然后根据补液前后染液质量守恒和各染料质量守恒公式建立染料拼色轧染的补液模型,计算出需要实时补加的各染料质量。实验验证结果表明:通过该补液模型进行补液后,轧染的25块织物色差均保持在0.5左右,且轧染液中各染料的质量浓度基本保持不变;而以原染液质量浓度补液后织物色差达到7左右,染料质量浓度降低了50%以上;该补液模型相比原染液补液体系的准确性较高。

关键词: 拼色染料, 补液模型, 轧染, 定量分析, 拉曼光谱

Abstract:

Objective The color matching of dyes is prone to fail in obtaining the desired color in practical production. In the process of continuous pad dyeing, it is necessary to adjust constantly the liquid replenishment to ensure stable dye concentration in the dye bath to avoid color difference between the head and tail in the dyeing process. However, the goal of precise control of the dyeing process cannot be achieved by relying on the experience of dyeing and finishing masters, and replenishment modelling in pad dyeing becomes necessary.
Method In order to explore the digital control method of the replenishment system of mixed dye in the pad dyeing process, the replenishment model was established based on the real-time monitoring of the dyeing process with mixed dyes using Raman spectroscopy. Firstly, the quantitative analysis model of mixed dye concentration with C.I. Reactive Red 195 (RR195) and C.I. Reactive Blue 194 (RB194) was established based on Raman spectroscopy monitoring and partial least square method (PLS). Then, the initial dye uptake rate of RR195 and RB194 were obtained under different dyeing processing conditions. Finally, the replenishment model of the combination pad dyeing was established to calculate the amount of each dye to be added in real-time according to the conservation of mass with dye solution and dyes before and after replenishment, and compared with the replenishment system through the concentration of the original dye solution.
Results The results showed that the correlation coefficients of RR195 and RB194 dyes in the correction set and prediction set in the quantitative analysis model were greater than 0.990 0 (Fig.4), and the root mean square error of cross validation (RMSECV) and the root mean squared errors of prediction (RMSEP) were 0.279 0 and 0.129 0, 0.115 0 and 0.054 5, respectively. The fitting curves of the correction set and prediction set of the two dyes demonstrated a high coincidence. This suggested that the established quantitative analysis model had a high prediction capability. The real-time monitoring of the dyeing process of RR195 and RB194 were achieved by using the quantitative analysis model, according to which the color matching dyeing process of RR195 and RB194 (at a mass ratio 1:1) were obtained in real time. It is assumed that the soaking time of the fabric in the pad dye solution is 6 s, and the initial dye-uptake rate of RR195 and RB194 were calculated as 28.10 and 36.63 mg/(g·min) respectively according to the dye-uptake curves. By using the formula of the replenishment model, it was found that the volume of dye solution to be replenished after dyeing each fabric (3.0 g) was 2.15 mL, and the mass of RR195 and RB194 dyes to be replenished were 13.80 and 16.36 mg, respectively. The color difference of 25 fabrics after the pad dyeing through the replenishment system is maintained at 0.5, and the concentration of RR195 and RB194 in the dye solution remains unchanged. However, the color difference of 25 fabrics after the pad dyeing with original replenishment model is about 7, and the dye concentration of RR195 and RB194 was reduced by more than 50%, which verifies the accuracy of the replenishment model.
Conclusion The experimental results of RR195 and RB194 with color matching dyeing verifies the accuracy of the quantitative analysis model and replenishment model. The developed replenishment model helps control the replenishment system digitally without relying on the human experience, and it minimizes the color difference between the head and tail in the pad dyeing process of color matching. The quantitative analysis model of mixed dye concentration established by Raman spectroscopy and PLS can be used for mixing most dyes without decomposition spectrum. This approach is applicable to further explorations on the influencing factors and mechanism of color matching dyes, and on studying the quantitative evaluation method of color matching dyes.

Key words: mixed dyes, replenishment model, pad dyeing, quantitative analysis, Raman spectroscopy

中图分类号:

TS193.5

代亚敏, 刘宏臣, 毛志平, 陆辉, 徐红, 钟毅, 周培文. 活性染料拼色轧染过程中补液模型的研究[J]. 纺织学报, 2023, 44(01): 136-141.

DAI Yamin, LIU Hongchen, MAO Zhiping, LU Hui, XU Hong, ZHONG Yi, ZHOU Peiwen. Replenishment modeling in pad dyeing process with mixed dyes[J]. Journal of Textile Research, 2023, 44(01): 136-141.

图/表 6

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