Full Dull Polyester Flame Retainer Yarn contains high levels of matte titanium dioxide and flame retardant masterbatch. The dispersion difficulty of the two powders is higher than that of ordinary full matte polyester yarn, which is prone to TiO ₂ aggregation and gloss deviation of the filament, ultimately forming bright and dark stripes on the fabric and dyed fabric. Uneven gloss not only damages the matte appearance of the fabric, but can also be accompanied by fluctuations in local flame retardant indicators in severe cases, making it the most common quality pain point in Full Dull Polyester Flame Retainer Yarn production and downstream weaving. The following article outlines feasible control measures from four dimensions: raw materials, spinning, post-processing, and testing, taking into account both matte uniformity and permanent flame retardant performance, suitable for fabric orders such as flame retardant fixtures, rail transit interiors, and hotel flame retardant curtains.
1. Raw material compatibility control, reducing uneven powder dispersion from the source
The gloss foundation of Full Dull Polyester Flame Retainer Yarn comes from uniformly dispersed matting agents, and the consistency of the mixing of flame retardant masterbatch and TiO ₂ matting masterbatch is the first level. Prioritize the use of compatible phosphorus based flame retardant masterbatch and fully matte masterbatch to avoid powder agglomeration; Stabilize the proportion of masterbatch added, fix the batch slicing and masterbatch ratio, and do not switch masterbatch suppliers arbitrarily. The raw material drying process strictly controls temperature and humidity to prevent moisture in the slices from causing fluctuations in melt viscosity, which in turn affects the fiber cross-section and light reflection effect. The same batch of Full Dull Polyester Flame Retainer Yarn must have a uniform TiO ₂ addition amount to avoid color differences caused by differences in extinction content between tube yarns.
2. Optimization of spinning process, stable single filament forming and consistent gloss
Spinning is the core process for controlling the uniform gloss of Full Dull Polyester Flame Retainer Yarn. The graded filtering components are matched with suitable filter materials to intercept TiO ₂ agglomerated particles, reduce nozzle clogging and single filament thickness fluctuations; Stabilize the temperature of the box, the speed and temperature of the blowing air, and ensure that each single filament has a consistent cooling rate, uniform crystallization, and uniform gloss. Control the spinning tension to stabilize and reduce the fluctuation of strip CV value; The fluctuating tension can cause deformation of the fiber cross-section, resulting in different light reflections and direct strip-shaped differences in brightness and darkness on the fabric surface. Regularly inspect the condition of each spindle position, distinguish between loose threads, floating threads, and spindle position deviations, and prevent the Full Dull Polyester Flame Retainer Yarn with abnormal gloss from being mixed into qualified tubes in individual spindle positions.
3. DTY false twisting and winding control to avoid poor gloss inside and outside the tube
Many Full Dull Polyester Flame Retardant Yarns are processed into DTY low elastic yarn for supply to weaving factories. The temperature of the false twisting hot box should not be too high, as high temperatures can cause slight decomposition of flame retardant components and uneven fiber shrinkage, resulting in tight spots and glossy streaks; Stable D/Y ratio and processing tension, uniform heat setting conditions for the entire batch of silk. The winding process controls the winding hardness to avoid the accumulation of pressure and heat on the inner layer of the cylinder, which may result in inconsistent gloss between the inner and outer layers of the cylinder. Mark the cylinder yarn by batch and ingot position, and use the same batch and ingot number when weaving the cylinder. Do not mix Full Dull Polyester Flame Retainer Yarn produced in different process periods.
4. Weaving and dyeing and finishing matching process to prevent the appearance of stripes in the later stage
Some of the differences in luster of the original silk are not obvious in the white blank, and are only exposed as cloth noodle flowers after dyeing. During the weaving of Full Dull Polyester Flame Retainer Yarn, the tension of warp and sizing is kept uniform, reducing the warp tension; Thoroughly removing oil agents before dyeing and finishing, uneven residue of oil agents can change surface reflection and form false stripes. Dyeing heating rate, stable pH of dyeing bath, and uniform dyeing of dispersed dyes; Full extinction fibers themselves have weak reflectivity, and even small differences in dyeing can be amplified. When making fabric samples, a fixed light source is used to detect the matte effect, and the standard light source box is checked to distinguish whether the uneven gloss of the original silk or the stripe caused by the dyeing and finishing process.
5. Establish gloss quality control system based on online and offline detection standards
Establish a sampling mechanism for Full Dull Polyester Flame Retardant Yarn: take fabric samples from each batch, pre dye, and verify the presence of barre streaks; Synchronize sampling of LOI flame retardant indicators to ensure that the matte adjustment process does not sacrifice flame retardant performance. Record the dispersion state of TiO ₂, dry data, and visual rating of gloss to form a batch quality file. For export orders, small batch trial weaving and dyeing should be done in advance, and the process should be locked in advance to reduce rework on large orders, meeting the dual requirements of Full Dull Polyester Flame Retainer Yarn matte appearance and flame retardant safety for tooling, rail transit, and curtain fabric customers.
