Journal of Textile Research ›› 2022, Vol. 43 ›› Issue (05): 18-25.doi: 10.13475/j.fzxb.20211109108

• Invited Column: Expert Opinion of the 11th China Textile Academic Conferenc • Previous Articles     Next Articles

One-bath pad dyeing technology for polyester/cotton fabric

LIU Yu1,2,3,4, XIE Ruyi1,2,3,4, SONG Yawei1,2,3,4, QI Yuanzhang5, WANG Hui5, FANG Kuanjun1,2,3,4()   

  1. 1. College of Textiles & Clothing, Qingdao University, Qingdao, Shandong 266071, China
    2. Collaborative Innovation Center for Eco-Textiles of Shandong Province and the Ministry of Education, Qingdao, Shandong 266071, China
    3. State Key Laboratory for Biofibers and Eco-Textiles, Qingdao, Shandong 266071, China
    4. Collaborative Innovation Center for Eco-Textiles of Shandong Province, Qingdao, Shandong 266071, China
    5. Lufeng Weaving and Dyeing Co., Ltd., Zibo, Shandong 255100, China
  • Received:2021-11-22 Revised:2022-02-23 Online:2022-05-15 Published:2022-05-30
  • Contact: FANG Kuanjun E-mail:13808980221@163.com

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Abstract:

To solve the problems of process complexity, high water and energy consumption, high carbon and waste water emissions in dyeing process of polyester/cotton fabric, a disperse/reactive dye one-bath two-step pad dyeing method of polyester/cotton was investigated. The stability of disperse/reactive mixed dye solution in different pH conditions was analyzed. The effects of baking temperature, baking time, pH, type and concentration of alkali, steaming time on fabric dyeing were discussed using Disperse Blue 79 and K, KN and M Reactive Dyes. The energy consumption of the one-bath pad dyeing process and traditional process were evaluated and compared. The results show that fabrics dyed using the one-bath two-step method achieve the same color depth compared with the traditional dyeing process. The rubbing fastness and washing fastness reach grade 4-5. Take Disperse Blue 79 and Reactive Blue 19 for example, compared with the traditional two-bath pad dyeing process, the one-bath pad dyeing process reduces water consumption by 45.5%, electricity consumption by 20.9%, heat consumption by 41.7% and CO2 emission by 40.6% per 10 000 m of polyester/cotton fabric.

Key words: polyester/cotton fabric, one-bath two-step method, pad dyeing, disperse dye, reactive dye, low carbon emission, color strength

CLC Number: 

  • TS193.6

Fig.1

Effect of pH value on stability of dyes solutions. (a) Effect of pH value on TSI value of dye solution; (b) Backscattering spectrum of dye solution at pH 4; (c) Backscattering spectrum of dye solution at pH 5; (d) Backscattering spectrum of dye solution at pH 6"

Tab.1

Effect of dyeing bath pH value on color index of dyed fabrics"

活性染料类型 染浴pH值 L* a* b* K/S值
K型 4 38.9 -1.4 -31.2 7.8
5 39.5 -1.5 -31.4 7.6
6 39.3 -1.0 -31.9 7.6
KN型 4 36.9 -0.7 -33.3 9.5
5 37.5 -0.9 -33.4 9.2
6 36.7 -0.7 -32.9 9.5
M型 4 36.0 -0.5 -31.4 9.5
5 36.5 -1.1 -32.1 9.5
6 36.4 -0.4 -31.9 9.3

Fig.2

Effect of baking temperature on K/S value of dyed fabrics"

Fig.3

Effect of baking time on K/S value of dyed fabrics"

Fig.4

Effect of NaOH concentration on K/S value of fabrics dyed"

Fig.5

Effect of Na2CO3 concentration on K/S value of fabrics dyed"

Tab.2

Effect of alkali concentration on color index of polyester yarns in fabric"

Na2CO3质量浓度/(g·L-1) L* a* b* K/S值
10 26.9 -1.4 -26.2 19.8
20 26.0 -1.1 -25.4 20.5
30 26.5 -1.5 -25.7 20.3
40 26.9 -1.5 -26.2 20.0
50 26.9 -1.5 -26.3 20.0

Fig.6

EDS spectrum of polyester and cotton in polyester/ cotton fabric before and after steaming. (a) Before steaming cotton in fabric; (b) After steaming cotton in fabric; (c) Before steaming polyester in fabric; (d) After steaming polyester in fabric"

Fig.7

Effect of steaming time on K/S value of fabric dyed"

Fig.8

Effect of steaming time on K/S value of fabrics dyed"

Fig.9

Polyester/cotton fabric ultra-depth picture(use only Reactive Blue 19). (a) Before steaming; (b) After steaming"

Tab.3

K/S value and color fastness of dyed fabrics"

活性
染料		 工艺
方法		 K/S值 耐摩擦色牢度/级 耐皂洗色牢度/级
干 湿 棉沾 变色
K型 两浴轧染 4.0 5 5 4~5 5
一浴轧染 4.0 5 4~5 4~5 5
KN型 两浴轧染 9.6 5 5 4~5 5
一浴轧染 9.5 5 4~5 4~5 5
M型 两浴轧染 8.1 5 5 4~5 5
一浴轧染 7.9 5 4~5 4~5 5

Tab.4

Energy consumption and CO2 emission by different processes"

工艺 水耗/t 电能消耗/
(kW·h)		 热能消耗/
GJ		 CO2排放量/
t
两浴轧染 399.3 408.3 63.8 7.4
一浴轧染 217.8 322.9 37.2 4.4
节省比例/% 45.5 20.9 41.7 40.6
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