HK1061262A1 - Dyeing and process of fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for dye-processing a fabric, not exhibiting discrepancy in patterns between the surface side and back surface side. <P>SOLUTION: This method for dye-processing the fabric comprises separating warp yarns wound on a same beam 5a into surface pile warp yarns 1 and back surface pile warp yarns 2 in sheet states, dyeing for forming the same pattern as the pattern expressed on the surface of the fabric, and then winding on a finish beam 5b. Since the pile warp yarns 1, 2 are drawn out under a fixed tension and transported at a same speed, the dyed patterns of the surface pile warp yarns and the back surface pile yarns do not get discrepancy. Therefore, the patterns expressed on the surface and back surface of the pile fabric are made so as not to form the discrepancy between the surface and the back surface. <P>COPYRIGHT: (C)2004,JPO

Description

Dyeing processing method of fabric

Technical Field

The invention relates to a dyeing processing method of fabrics such as towels, toweling coverlets, sheets, clothes grey cloth, curtains, carpets and the like.

Background

The fabric is formed by warp and weft yarns according to a certain rule to form a fabric weave which is orthogonal up and down, and the typical production steps comprise a warping step, a weaving step and a dyeing step.

The warping step is a preparatory step of a weaving step, in which the necessary number of warp yarns is adjusted, and the warp yarns are wound around a warp beam or the like while being oriented by appropriately adjusting the spacing, length, tension, and the like. The weaving step is a step of forming a fabric weave, and warp yarns and weft yarns warped in the warping step are vertically orthogonal to each other, so that the fabric weave is completed. The dyeing step is a step of dyeing the yarn or fabric with a dye or the like by a method such as dip dyeing or stamp (flower) dyeing.

The dyeing step includes a case of completing the pre-dyeing of the fabric and a case of completing the post-dyeing of the fabric, and specifically includes: (1) a method of expressing a pattern of a yarn (spun-dyed yarn) dyed in stages with a dobby loom or a jacquard loom; (2) applying a method of printing and dyeing a finished fabric to express a design; and (3) a method of dip-dyeing and coloring the finished fabric.

However, the above dyeing method has the following difficulties. That is, according to the method (1), even if a plurality of colors are used for the entire fabric, since the yarns are single-colored at one yarn, it is difficult to express patterns having various and complicated colors. Further, the inner layer of the fabric may show a pattern symmetrical to the surface layer, and may not show a pattern only on the surface layer, or may show a completely different pattern on the surface and the inside.

In addition, according to the method (2), although various and complicated patterns can be expressed, the dye can penetrate only the surface layer of the fabric blank, and the depth of color is less than that of the dope-dyed fabric. It is clearly visible from thick or long pile fabrics such as pile fabrics, and also causes pattern deformation due to falling of pile or nap during dyeing. In order to solve the above problems, a method of applying a printing after cutting pile (cutting off the pile or pile surface layer) is possible, and there is a problem that the fabric becomes thin, the dye penetrates into the inside somewhat but not completely, and the water retentivity and heat retaining property of the fabric itself are lowered by cutting off the pile or pile surface layer.

The pile fabric is 1 type of fabric, and is composed of warp yarns and weft yarns composed of pile warp yarns and blank yarns, and pile (pile loops) is formed on the surface of the fabric, so that water retention, excellent touch, heat retention, and the like can be improved. The pile is a tension which is applied to the pile warp yarns more loosely than the blank yarns, whereby a part of the pile warp yarns is formed protruding in a loop shape on the surface layer of the fabric.

Further, according to the method (3), the whole can be dyed only in a single color, and in the case of pattern representation, it is extremely troublesome to make a design or represent the pattern or characters in the weaving method or to perform a post-step represented by embroidery.

Therefore, as described in Japanese patent application laid-open No. 5-86538, a method for producing a woven fabric is disclosed in which a complicated pattern with diversified colors can be expressed and the interior of the woven fabric can be dyed. The method for producing a woven fabric described in Japanese unexamined patent publication No. 5-86538 is characterized in that: a method for producing a printed towel fabric, wherein pile warp yarns are divided into 2 groups of yarn sheets, each of the yarn sheets is printed, any one of the 2 groups of pile warp yarns is arranged on the surface layer side, the other group is arranged on the inner layer side, and the ground yarn and the weft yarn are woven simultaneously to form a towel fabric with pile on both sides, whereby the towel fabric is printed so that the front and back are asymmetrical on both sides of the fabric according to the above-mentioned printed pattern, characters or both of the pile warp yarns.

Specifically, as shown in fig. 7, in step 1, pile warp yarns 1 of group 1 wound around an empty warp beam 11a are transported in a yarn sheet, dyed in a predetermined pattern by a plurality of flat screen printing machines 12, and wound around a 1 st warp beam 13 a. Also in step 2, the 2 nd group of pile warp yarns 2, which are printed on the empty warp beam 11b, are wound on the 2 nd warp beam 13 b. Subsequently, in the 3 rd step, the yarns are simultaneously fed out so that the 1 st warp beam 13a and the 2 nd warp beam 13b are in an up-and-down relationship with each other, and the yarn sheets 1 and 2 are wound around the 1 weaving warp beam (finishing warp beam) 5, thereby performing the weaving step.

According to the above method, the printing pattern of the pile warp yarn divided into 2 sets of yarn sheets can be expressed as it is on the surface layer of the terry towel, and thus a complex pattern of multiple colors can be expressed. In addition, the pile warp yarns are printed with the yarn sheet, whereby the pile yarns in the printed portion can be colored to the root portion thereof, and thus the pile root portion of the terry cloth can be colored. The pile warp yarns are divided into 2 sets of yarn sheets, each set is subjected to printing, and any one set of the 2 sets of the pile warp yarns subjected to printing is arranged on the surface layer side, the other set is arranged on the back layer side, and a towel fabric with pile on both sides is woven. Therefore, the patterns, characters, or both printed by the warp yarns can be expressed on both sides of the fabric asymmetrically in the front and back.

However, since the pile warp yarns of the 1 st group and the pile warp yarns of the 2 nd group are wound around the respective warp beams (the 1 st warp beam and the 2 nd warp beam) in the printing step, it is difficult to maintain the same tension of the two pile warp yarns. The tension of the yarn varies depending on subtle differences in the peripheral environments such as temperature and humidity.

Therefore, when the pile warp yarns of the two sets are arranged on the surface layer and the other on the back layer side of the towel fabric, the pattern is shifted between the surface layer and the back layer of the towel fabric. Further, when the 1 st and 2 nd warp beams are wound around the same weaving beam, it takes time and is difficult to match the pattern of the surface layer with the pattern of the back layer.

When the patterns on the front and back sides of the terry towel are shifted and one terry towel is cut, the patterns on the back side are cut halfway as shown in fig. 8(2) and (3), and the terry towel cannot be sold. Generally, when the patterns on the front and back surfaces are shifted by more than 5mm, they cannot be sold as a commercial product.

In addition, in the method for producing a fabric described in Japanese patent application laid-open No. 5-86538, a flat screen printing machine is used as a printing device, and dyeing is performed by several flat screen printing machines in a color-by-color manner. The flat screen textile printing machine stops the belt during the sliding (squeegeeing) and repeats the movement after the completion of the sliding, so that the warp beam can be repeatedly and promptly stopped and advanced for pile warp yarns of several hundred meters long, but the pattern shift such as printing cannot be sold as a commercial product even if it is 1cm, so that it is extremely difficult to request the precise feeding of the warp beam. In addition, there is a possibility that the surface pile warp yarns and the back pile warp yarns extend differently in response to the emergency stop and the emergency advance, and the pattern may be shifted in the same manner.

Further, when printing is performed by a flat screen printing machine, the pile warp sheet must be stably fixed to the belt with paste so as not to be displaced due to slippage. However, in the subsequent weaving step, when the pile warp yarns are fed to the loom, the pile warp yarns must be completely separated by being individually fed to a 50-comb-shaped reed of 3.79cm, but it is a very difficult technique to completely separate the pile warp yarns without breaking when the yarns having the paste adhered to the belt are peeled from the belt after drying or when the yarns are peeled because they are also adhered to each other by the paste. Even if the reed is arranged to separate the yarns before drying, the yarns are dyed with various colors due to printing, so that the reed pollutes subsequent yarns.

In addition, printing on flat screens leaves printing paste between the yarns of the pile warp, which is not absorbed by the yarns and contaminates the inside of the screen and the subsequent yarns. As described above, it is extremely difficult to apply printing to a sheet-like yarn using a flat screen printing machine.

Disclosure of Invention

In view of the above problems, an object of the present invention is to provide a method for dyeing a fabric without shifting the surface pattern and the back pattern.

In order to solve the above problems, the present invention is a method for dyeing a fabric characterized in that a warp yarn wound on the same warp beam is separated into a sheet-like surface yarn and a back yarn, dyed, and then wound on the same finished warp beam. The surface layer yarn and the inner layer yarn wound on the same warp beam are wound on the same finished warp beam, so that the surface layer yarn and the inner layer yarn can be wound under the same ambient environment such as temperature, humidity and the like, and the tension and the moving speed of the surface layer yarn and the inner layer yarn between the warp beams can be kept the same. Therefore, since the patterns dyed in the same position of the surface layer yarn and the back layer yarn from the finishing beam are simultaneously wound around the finishing beam between the beams, the patterns appearing on the surface layer side and the back layer side of the fabric are not shifted.

Alternatively, the warp yarn hung on the creel may be separated into the surface yarn and the back yarn in a sheet-like manner, dyed under the same tension and at the same speed, and then wound on the same finished beam. Since the patterns dyed by the surface layer yarn and the back layer yarn from the same position at the distance from the finish warp beam are simultaneously wound around the finish warp beam by setting the same tension of the surface layer yarn and the back layer yarn and setting the same moving speed, the patterns developed on the surface layer side and the back layer side of the fabric are not shifted.

The dyeing method may be any of various dyeing methods such as manual screen printing, automatic screen printing, rotary screen printing, roll printing, transfer printing, discharge printing, resist printing, wax printing, and injection printing, but a non-contact printing machine in which dyeing is performed using a non-contact fabric is preferred as the front end. That is, since the non-contact type ink jet printing or the like is dyed by ejecting a dye onto a non-contact fabric, tension fluctuation of warp does not occur, and it is not necessary to fix sheet-like warp to a belt with paste, such as a flat screen printing machine. Thus, no separate process step is required to be applied to the yarns prior to weaving.

Further, since the printing can be performed while transferring the sheet-like warp at a constant speed without repeating the emergency stop and the emergency advance, the printing pattern is not easily shifted and the warp is not stretched to an excessive degree. Therefore, the patterns of the surface and the back of the fabric are not shifted.

Further, the flat screen textile machine does not need to directly contact the warp yarns by sliding, and therefore, as described above, the printing paste remaining between the warp yarns contaminates the back layer of the subsequent screen and causes problems such as contamination of the subsequent warp yarns. In addition, dyes and pigments may be used as the raw material for dyeing.

When pile yarns are used as the surface yarn and the lining yarn, the surface yarn of the fabric is hidden by the pile formed by the surface yarn, and the lining yarn of the fabric is hidden by the pile formed by the lining yarn, so that the dyed pattern of the surface yarn can be only expressed on the surface of the fabric, and the dyed pattern of the lining yarn can be only expressed on the lining of the fabric.

In addition, when the surface layer yarn and the inner layer yarn are dyed in different patterns, patterns are formed on the surface layer and the inner layer of the fabric, and the patterns can be represented on the surface layer and the inner layer in different patterns.

Drawings

FIG. 1 is a view showing a dyeing step in the present example.

Fig. 2 is a schematic view of fig. 1.

FIG. 3 is a view showing a dyeing step in another embodiment.

FIG. 4 is a view showing a dyeing step in still another embodiment.

Fig. 5 is a cross-sectional view of the weave of the pile fabric.

Fig. 6 is a perspective view of a pile fabric.

FIG. 7 is a schematic view of a known dyeing step.

Fig. 8(1) a plan view of the surface of a known pile fabric (a) without shifting the patterns of the surface and the back layers, (b) a plan view of the back layers thereof, (2) a plan view of the surface of a known pile fabric (a) with shifting the patterns of the surface and the back layers, (b) a plan view of the back layers thereof, (3) a plan view of the surface of a known pile fabric (a) with shifting the patterns of the surface and the back layers thereof, and (b) a plan view of the back layers thereof.

Detailed Description

Hereinafter, embodiments of the present invention will be described with reference to the drawings. An example of the method for dyeing a pile fabric according to the present invention will be described. As shown in fig. 5, the pile fabric is formed by a warping step and a weaving step in a fabric structure in which warp yarns composed of the surface pile warp 1, the back pile warp 2, and the ground yarn 3 are orthogonal to the weft yarns 4, and if necessary, other steps such as a sizing step and an embroidering step may be performed.

As shown in fig. 1 and 2, the method for dyeing a pile fabric is a method in which the warp yarn of a warp beam 5a after a warping step is separated into a sheet-like surface pile warp yarn 1 and back pile warp yarn 2, which are dyed separately and then wound around a single weaving completion warp beam 5 b.

That is, the warp yarn of the warp beam 5a is separated into the front pile warp yarn 1 and the back pile warp yarn 2, and formed into a sheet shape by the reed 6. The sheet-like lengthwise yarns 1, 2 are dyed by an ink jet printer 7, dried by a dryer 8 provided on the downstream side thereof, and then wound around the same finished beam 5 b.

The ink jet printer 7 dyes the surface pile warp 1 and the back pile warp 2, which are oriented in a sheet-like manner, in the same pattern as the pattern expressed on the finished pile fabric surface. At this time, the sheet-like front pile warp 1 and back pile warp 2 are dyed at the same positions of the distance up to the completion of the warp beam 5b, with the patterns of the pile fabric facing the front and back layers being applied. Further, it is preferable that the pattern on the fabric surface is curled and deflected in the warp direction by pile formation, and the adjusted pattern is dyed to the surface layer pile warp yarn 1 in consideration of the deflection ratio. Further, although the ink jet printer 7 is used as the dyeing apparatus, another dyeing apparatus may be used.

Further, the sheet-like front pile warp 1 and back pile warp 2 are arranged vertically, but they may be arranged laterally as shown in fig. 3. In this case, both can be dyed simultaneously with one ink jet printer.

The finishing warp beam 5b on which the surface pile warp yarn 1 and the back pile warp yarn 2 having undergone the dyeing step are wound is subjected to the next weaving step. The weaving step is a step of forming a weave, and is performed by using a loom (not shown). The surface pile warp 1 and the back pile warp 2 wound on the finished warp beam 5b are set on a loom in a warping step such as a warping process, and the ground yarn 3 and the weft yarn 4 are set on the loom. Then, a fabric structure composed of the surface pile warp 1, the back pile warp 2, the ground yarn 3, and the weft yarn 4 is formed by basic operations of the shedding motion, the weft insertion motion, and the beating-up motion of the loom.

With the above-described structure, when the warp yarn is wound from the same warp beam 5a onto the same finishing warp beam 5b, the surface pile warp yarn 1 and the back pile warp yarn 2 between the warp beams 5a, 5b can be drawn out in a sheet form at the same moving speed while maintaining a constant tension, and therefore, when the yarn is dyed by the ink jet printer 7 between the warp beams 5a, 5b, the yarn can be simultaneously wound onto the finishing warp beam 5b, and the dyed pattern is not shifted between the surface pile warp yarn 1 and the back pile warp yarn 2. Therefore, the patterns expressed on the front and back layers of the pile fabric are not displaced.

Since the dyed surface pile warp yarns 1 and back pile warp yarns 2 are woven by winding them around the finished warp beam 5b while maintaining their arrangement, spacing, and tension, the patterns of the dyed surface pile warp yarns 1 and back pile warp yarns 2 in the form of a sheet are not shifted and can be displayed on the front and back layers of the fabric. As shown in fig. 6, since the portion of the front pile warp yarn 1 on the back side of the weft yarn 4 is hidden by the pile of the back pile warp yarn 2, the color of the front pile warp yarn 1 is less likely to affect the back layer. On the other hand, the part of the pile warp yarn 2 passing through the back layer on the surface layer side of the weft yarn 4 is hidden by the pile of the pile warp yarn 1 passing through the surface layer, so that the color of the pile warp yarn 2 passing through the back layer does not easily affect the surface layer. In addition, unlike the case of using the pre-dyed yarns to express the pattern, the pattern can be woven easily regardless of the arrangement of the yarns, and at this time, different patterns can be expressed on the front and back layers by dyeing the front pile warp yarns 1 and the back pile warp yarns 2 with different patterns.

The present invention is not limited to the above-described embodiments, and various modifications and changes may be made to the above-described embodiments within the scope of the present invention. For example, in the above embodiment, the warp beam 7 after warping is rewound to the finished warp beam 5b and is dyed, but as shown in fig. 4, the warp beam may be dyed in the warping step. The warp sheet hung on the beam frame is separated into surface yarn and inner yarn, and the two yarns are dyed under the condition of same tension and speed, and then wound on the same finished beam.

The warping step is a step of correcting the number of warp yarns required, aligning the warp yarns in a sheet form by appropriately adjusting the spacing, length, tension, and the like during weaving in the weaving step, and winding the warp yarns around a finishing beam for weaving. First, as shown in fig. 4, a necessary number of bobbins or cones 9 are hung on a creel 10 (a frame for a large number of bobbins 8 or the like is set) for each of the surface pile warp 1 and the back pile warp 2, and the yarns are extended in 2 pieces. One sheet-like yarn is set as a surface pile warp yarn 1, and the other sheet-like yarn is set as a back pile warp yarn 2. At this time, the sheets 1 and 2 are stretched after measuring a predetermined length at a predetermined yarn interval and a predetermined tension, the yarn interval is adjusted by the reed 6, and the sheet-like front pile warp 1 and back pile warp 2 are wound around the same finishing warp beam 7. The ground yarn 3 is also a yarn from a bobbin or cone 9 which is warped in a warping step and wound on a beam.

The step of dyeing the warps 1 and 2 is provided in the middle of the warping step described above, that is, the warp is drawn out from the bobbin or cone 8 at a constant yarn interval and under a constant tension, wound around the warp beam 7, and an ink jet printer 7 as a dyeing device is provided on the sheet-like oriented surface pile warp 1 and back pile warp 2, and a dryer 8 is provided on the downstream side of the yarn flow.

According to the above configuration, since the surface pile warp yarn 1 and the back pile warp yarn 2 are dyed at the same tension and the same speed and wound on the same warp beam as described above, no pattern shift occurs in the surface and back layers of the pile fabric.

The method of dyeing the fabric is not limited to the pile fabric, and the fabric may be a fabric in which no pile is formed.

Effects of the invention

As is apparent from the above description, according to the present invention, the surface pile warp yarns and the back pile warp yarns wound on the same warp beam are drawn out in a sheet-like manner, dyed in the same pattern as that expressed on the fabric surface, and then wound on the same finished warp beam, and the tension and the moving speed of the surface pile warp yarns and the back pile warp yarns between the warp beams are maintained in the same manner, so that the pattern of the surface pile warp yarns and the pattern of the back pile warp yarns are not shifted, and therefore, the patterns expressed on the surface and back of the pile fabric can be prevented from being shifted.

Claims (8)

1. A dyeing processing method of fabric is characterized in that: the warp yarn is separated into a sheet-like surface yarn and a sheet-like back yarn, dyed under the same tension and at the same speed, and wound on the same finished beam.

2. The dyeing process of claim 1 wherein said warp yarns are wound on the same beam.

3. The dyeing process of claim 1 wherein said warp yarns are hung from a creel.

4. The dyeing processing method according to claim 1, wherein an ink-jet printer for applying dyeing by non-contact with a nozzle to a fabric is used as the dyeing apparatus.

5. The dyeing processing method according to claim 2, wherein an ink-jet printer for applying dyeing by non-contact with a nozzle to a fabric is used as the dyeing apparatus.

6. The dyeing process according to any one of claims 1 to 4, wherein the surface yarn and the back yarn are pile yarns.

7. The dyeing method according to any one of claims 1 to 4, wherein the surface layer yarn and the back layer yarn are subjected to different patterns.

8. The method of claim 5, wherein the surface yarn and the back yarn are patterned differently.