Method for Preparing Untwisted, Hollow, High-Count Textiles and Method for Recovering the Solute in an Alkaline Lysis Solution

Abstract

The present invention discloses a method for preparing untwisted, hollow, high-count textiles comprising the following steps: a. preparing an alkaline degradable slice; b. preparing a blended spun melt; c. preparing an easily alkaline soluble and degradable fiber by spinning; d. preparing the textiles or an embroidered article. A method for recovering the solute in an alkaline lysis solution comprises an alkaline lysis solution obtained after the degradation of the easily alkaline soluble and degradable fiber is subjected to an acid precipitation, so as to produce terephthalic acid, wherein the waste water obtained by filtering meets the emission standard and is introduced to a biochemistry processing system.

Claims

1. A method for preparing untwisted, hollow, high-count textiles, characterized in that the method comprises the following steps: a. preparing an alkaline degradable slice: during the polymerization of polyester raw materials, adding 5-sodium sulfonate-isophthalate polyethylene glycol ester containing totally 1-20 wt % of polymers and isophthalate containing totally 1-20 wt % of polymers, stirring and heating the obtained mixture to 200-260 C., so as to form a slurry; transforming the obtained mixture into a reactor, meanwhile adding polyethylene glycol containing 1-20 wt % of polymers, so as to dilute and cool the mixture to 180-260 C.; sequentially adding polyethylene glycol having molecular weight of 4000-6000 into the reactor for the period of 30-60 min under stirring, wherein the amount of polyethylene glycol is 1-20% of the total weight of the polymers; heating the mixture up to 200-260 C. such that the mixed raw materials are polymerized under vacuum; finally, the polymerized alkaline degradable slice successively being casted into a strip, cooled, pelletized, dried and screened, wherein the intrinsic viscosity of the alkaline degradable slice is in the range of 0.45-0.75; b. preparing a blended spun melt: during the preparation of a spun melt, adding an easily hydrolysable substance into the spun melt to blended therein, wherein the weight ratio of the alkaline degradable slice to the easily hydrolysable substance is in the range of 100:0-60:40; during the alkaline dissolution and degradation, said easily hydrolysable substance being filtered partly or dissolved out, such that micropores are formed on the surface of a fiber; c. preparing an easily alkaline soluble and degradable fiber by spinning, the easily alkaline soluble and degradable fiber comprising filament yarn, staple fiber and fiber strips; d. the staple fiber consisting of natural fiber and chemical fiber being combined with the filament yarn in the easily alkaline soluble and degradable fiber, then being reverse twisted, wherein the degree of the reverse twist substantively being the same as that of the instinct twist degree of the staple fiber; weaving textiles, then taking the textiles into an alkali solution so as to dissolve the easily degradable fibers, thereby obtaining an untwisted textiles; alternatively, by open-end spinning or non-open-end spinning manner, the easily alkaline soluble and degradable fiber filament yarn or yarn being peripherally wrapped by periphery fibers, so as to produce a core-spun yarn, then the core-spun yarn being woven into cloth, and finally the cloth being immersed into an alkali solution, so as to dissolve the easily alkaline soluble and degradable fiber, thereby obtaining a hollow textiles; alternatively, the easily alkaline soluble and degradable fiber being spinning with a nature fiber or synthetic fibers together, or the fiber strip of the easily alkaline soluble and degradable fiber being combed with a cotton fiber strips or a hemp fiber strips, so as to form a yarn for weaving a cloth; then the cloth being immersed into an alkali solution, so as to dissolve the easily alkaline soluble and degradable fiber, thereby obtaining a yarn high-count textile; alternatively, making the easily alkaline soluble and degradable fiber into a non-woven fabric, and then making the non-woven fabric into an embroidery base cloth, then the embroidery base cloth being embroidered by using a embroidery thread so as to form a variety of patterns; then the non-woven fabric embroidered with patterns being immersed into an alkali solution, so as to dissolve the easily alkaline soluble and degradable fiber, thereby obtaining an embroidered article.

2. The method for preparing untwisted, hollow, high-count textiles of claim 1, characterized in that the easily hydrolysable substance is an alkaline degradable substance.

3. The method for preparing untwisted, hollow, high-count textiles of claim 2, characterized in that the temperature of the spinning in step c is in the range of 270-300 C.

4. The method for preparing untwisted, hollow, high-count textiles of any one of claim 1-3, characterized in that the alkaline solution used in the step d is sodium hydroxide solution.

5. A method for recovering the solute in an alkaline lysis solution during the preparation of the untwisted textiles, characterized in that the alkaline lysis solution obtained after the degradation of the easily alkaline soluble and degradable fiber is introduced through a grid into an adjusting pool, then the alkaline lysis solution in the adjusting pool is pumped into an acid precipitation tank via a lift pump; an acid liquid is pumped into the acid precipitation tank by an acid adding pump; the acid liquid and the alkaline lysis solution are stirred in the acid precipitation tank, thereby a waste water having pH of 3-4 is produced; meanwhile, terephthalic acid is produced; after the reaction of the acid liquid and the alkaline lysis solution is completed sufficiently, the waste water in the acid precipitation tank is introduced into a plate-and-frame filter press so as to be filtered, such that terephthalic acid is separated therefrom; the waste water obtained by filtering via the plate-and-frame filter press is finally introduced into a biochemistry processing system so as to meet the discharge standard.

6. A method for recovering the solute in an alkaline lysis solution during the preparation of the hollow textiles, characterized in that the alkaline lysis solution obtained after the degradation of the easily alkaline soluble and degradable fiber is introduced through a grid into an adjusting pool, then the alkaline lysis solution in the adjusting pool is pumped into an acid precipitation tank via a lift pump; an acid liquid is pumped into the acid precipitation tank by an acid adding pump; the acid liquid and the alkaline lysis solution are stirred in the acid precipitation tank, thereby a waste water having pH of 3-4 is produced; meanwhile, terephthalic acid is produced; after the reaction of the acid liquid and the alkaline lysis solution is completed sufficiently, the waste water in the acid precipitation tank is introduced into a centrifugal filter so as to be filtered, such that terephthalic acid is separated therefrom; the waste water obtained by filtering via the centrifugal filter is finally introduced into a biochemistry processing system so as to meet the discharge standard.

7. A method for recovering the solute in an alkaline lysis solution during the preparation of the high-count textiles, characterized in that the alkaline lysis solution obtained after the degradation of the easily alkaline soluble and degradable fiber is introduced through a grid into an adjusting pool, then the alkaline lysis solution in the adjusting pool is pumped into an acid precipitation tank via a lift pump; an acid liquid is pumped into the acid precipitation tank by an acid adding pump; the acid liquid and the alkaline lysis solution are stirred in the acid precipitation tank, thereby a waste water having pH of 3-4 is produced; meanwhile, terephthalic acid is produced; after the reaction of the acid liquid and the alkaline lysis solution is completed sufficiently, the waste water in the acid precipitation tank is introduced into a centrifugal filter so as to be filtered, such that terephthalic acid is separated therefrom; the waste water obtained by filtering via the membrane system is finally introduced into a biochemistry processing system so as to meet the discharge standard.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention will be further described with reference to the following drawings. It is noted that these drawings cannot be considered to limit the present invention in any aspects.

[0026] FIG. 1 schematically shows the structure of the device for recovering the solute in an alkaline lysis solution of the first embodiment.

[0027] FIG. 2 schematically shows the structure of the device for recovering the solute in an alkaline lysis solution of the second embodiment.

[0028] FIG. 3 schematically shows the structure of the device for recovering the solute in an alkaline lysis solution of the third embodiment.

DETAILED DESCRIPTION OF THE INVENTION

[0029] The present invention will be described with reference to the particular examples below.

EXAMPLE 1

[0030] The method for preparing untwisted textiles comprises the following steps:

[0031] a. preparing an alkaline degradable slice: during the polymerization of polyester raw materials, 5-sodium sulfonate-isophthalate polyethylene glycol ester containing totally 5 wt % of polymers and isophthalate containing totally 5 wt % of polymers were added, the obtained mixture was stirred and heated to 230 C., so as to form a slurry; the obtained mixture was transformed into a reactor, meanwhile adding polyethylene glycol containing 5 wt % of polymers, so as to dilute and cool the mixture to 210 C.; sequentially polyethylene glycol having molecular weight of 6000 was added into the reactor for the period of 50 min under stirring, wherein the amount of polyethylene glycol was 5% of the total weight of the polymers; under atmosphere, the mixture was heated up to 230 C. such that the mixed raw materials were polymerized under vacuum; finally, the polymerized alkaline degradable slice successively was casted into a strip, cooled, pelletized, dried and screened, wherein the intrinsic viscosity of the alkaline degradable slice was 0.55;

[0032] b. preparing a blended spun melt: during the preparation of a spun melt, an easily hydrolysable substance was added into the spun melt so as to blend therein, wherein the weight ratio of the alkaline degradable slice to the easily hydrolysable substance was 100:0;

[0033] c. spinning: preparing an easily alkaline soluble and degradable fiber by spinning, wherein the easily alkaline soluble and degradable fiber was filament yarn; wherein spinning process and the treatment step after the spinning process were as below: after conventional spinning process FDY at 285 C., a filament yarn soluble in alkaline solution was obtained; wherein specification of the fiber: 5.5 tex/24F fineness, 3.8cn/dtex tensile strength; 20% break elongation;

[0034] d. preparing untwisted towel: 12 s cotton yarn having z twists and 650 twist/m was combined with the filament yarn of the easily alkaline soluble and degradable fiber having 5.5tex/24F fineness, and then twisted inversely further 600 twist/m on a twister, the obtained yarn was used to weave the warp of the towel, so as to prepare a towel.

[0035] It is noted that, in the overflow tank, during the pre-treatment process in the towel, 4 g/L of 100% NaOH was added at 110 C. for 60 min, and the other additions were the same as those used in the conventional pre-treatment process; the dissolution of the easily alkaline soluble and degradable fiber, the later dyeing and the pro treatment process were the same as those for conventional cotton towel.

[0036] As shown in FIG. 1, the step of recovering the solute in an alkaline lysis solution during the preparation of the untwisted textiles was as below: the alkaline lysis solution obtained after the degradation of the easily alkaline soluble and degradable fiber was introduced through a grid into an adjusting pool, then the alkaline lysis solution in the adjusting pool was pumped into an acid precipitation tank via a lift pump; an acid liquid was pumped into the acid precipitation tank by an acid adding pump; the acid liquid and the alkaline lysis solution were stirred in the acid precipitation tank, thereby a waste water having pH of 3-4 was produced; meanwhile, terephthalic acid was produced; after the reaction of the acid liquid and the alkaline lysis solution was completed sufficiently, the waste water in the acid precipitation tank was introduced into a plate-and-frame filter press so as to be filtered, such that terephthalic acid was separated therefrom; the waste water obtained by filtering via the plate-and-frame filter press was finally introduced into a biochemistry processing system so as to meet the discharge standard. The grid was mainly used for intercepting the larger particle and other pollutants having a larger diameter in water, such as cotton yarn, cloth and other floating debris; the adjusting pool was used for buffering the amount of water, homogenizing the water, settling the larger solid particles, so as to facilitate the subsequent treatment processes. It was further noted that, the filtrate obtained by the plate-and-frame filter press had a greatly reduced sewage COD, increased BOD5/COD value and increased biodegradability. The terephthalic acid separated by filtering and dehydration via the plate-and-frame filter press was washed or not washed (as needed) and then stored in a package for transportation.

EXAMPLE 2

[0037] The method for preparing hollow textiles comprises the following steps:

[0038] a. preparing an alkaline degradable slice: during the polymerization of polyester raw materials, 5-sodium sulfonate-isophthalate polyethylene glycol ester containing totally 4 wt % of polymers and isophthalate containing totally 3 wt % of polymers were added, the obtained mixture was stirred and heated to 230 C., so as to form a slurry; the obtained mixture was transformed into a reactor, meanwhile adding polyethylene glycol containing 5 wt % of polymers, so as to dilute and cool the mixture to 210 C.; sequentially polyethylene glycol having molecular weight of 6000 was added into the reactor for the period of 50 min under stirring, wherein the amount of polyethylene glycol was 3% of the total weight of the polymers; under atmosphere, the mixture was heated up to 230 C. such that the mixed raw materials were polymerized under vacuum; finally, the polymerized alkaline degradable slice successively was casted into a strip, cooled, pelletized, dried and screened, wherein the intrinsic viscosity of the alkaline degradable slice was 0.61;

[0039] b. preparing a blended spun melt: during the preparation of a spun melt, an easily hydrolysable substance was added into the spun melt so as to blend therein, wherein the weight ratio of the alkaline degradable slice to the easily hydrolysable substance was 90:10; during the alkaline dissolution and degradation, said easily hydrolysable substance was filtered partly or dissolved out, such that micropores are formed on the surface of a fiber;

[0040] c. spinning: preparing an easily alkaline soluble and degradable fiber by spinning, wherein the easily alkaline soluble and degradable fiber was filament yarn; wherein spinning process and the treatment step after the spinning process were as below: after conventional spinning process FDY at 285 C., a filament yarn soluble in alkaline solution was obtained; wherein specification of the fiber: 5.5tex/24F fineness, 2.5cn/dtex tensile strength; 25% break elongation;

[0041] d. preparing a hollow textiles: in order to prepare a hollow textiles of an easily alkaline soluble and degradable fiber, firstly, a core-spun yarn was produced, wherein the core-spun yarn consisted of two different fibers respectively as a periphery layer and a core layer, one fiber was used as periphery fiber tightly wrapped around the easily alkaline soluble and degradable fiber; the open-end spinning or non-open-end spinning manner comprised ring spinning, siro spinning, compact spinning, jet vortex spinning, friction spinning and other spinning methods; for example, a core spun yarn can be spun through the ring spinning machine of the modified non-open-end spinning process; the easily degradable alkali-soluble fiber was through yarn guide, then directly fed to front roller via a collection roller, rather than via the aggregator of the front roller; the coated cotton fiber wrapped on the surface of the easily alkaline soluble and degradable fiber by a conventional spinning method; when the cotton fiber broken away from the jaw of the front roller, it was subjected to a reduced tension, and the easily alkaline soluble and degradable fiber without formaldehyde residue was always between the winding positions of the roller and maintained with a certain tension. Thereby, the cotton fiber wrapped on the surface the core of the yarn, and was twisted and winded into a shape. Thereby, the spinning process was finished. The obtained core-spun yarn had 32 s yarn, wherein the easily alkaline soluble and degradable fiber without formaldehyde residue was 30 d.

[0042] (1) a dyed and spun hollow fabric

[0043] 32 s yarns of the core-spun yarns containing the easily alkaline soluble and degradable fiber without formaldehyde residue were combined together to form a cheese yarn; in the jar at a high temperature and a high pressure, the easily alkaline soluble and degradable fiber without formaldehyde residue in the yarn was dissolved, was yarn dyed and was spun to form a dyed and spun hollow fabric.

[0044] (2) a dyed hollow fabric

[0045] The dyed hollow fabric was prepared as below. The core-spun yarn made from the hollow yarn containing the easily alkaline soluble and degradable fiber without formaldehyde residue was spun; since the hollow yarn fabric was spun from the core-spun yarn, the fabric with the easily alkaline soluble and degradable fiber being not removed was actually not a hollow yarn fabric; only when the a series of processes comprising dissolving to remove were carried out, and the easily alkaline soluble and degradable fiber was removed from the hollow yarn fabric, such that only the hollow yarn was resided, the hollow yarn fabric was actually obtained.

[0046] Wherein the hollow fabric was spun by using a conventional weaving process; that is, the core-spun yarn was directly or after starching, spun into a fabric, which comprises a knitted fabric and a woven fabric. After the dissolving and dying process were carried out, a dyed fabric, towel and the like were obtained.

[0047] For example, 32 s of cotton yarn containing 30 D of the easily soluble fiber was woven into a plain knit jersey; in the overflow tank, during the pre-treatment process of the fabric, 5 g/L of 100% NaOH was added at 110 C. for 60 min, and the other additions were the same as those used in the conventional pre-treatment process; the dissolution of the easily alkaline soluble and degradable fiber, the later dyeing and the pro-treatment process were the same as those for conventional cotton Knitted fabrics.

[0048] Finally, 180 g/m2 of the hollow yarn jersey fabrics were obtained.

[0049] As shown in FIG. 2, the step of recovering the solute in an alkaline lysis solution during the preparation of the hollow textiles was as below: the alkaline lysis solution obtained after the degradation of the easily alkaline soluble and degradable fiber was introduced through a grid into an adjusting pool, then the alkaline lysis solution in the adjusting pool was pumped into an acid precipitation tank via a lift pump; an acid liquid was pumped into the acid precipitation tank by an acid adding pump; the acid liquid and the alkaline lysis solution were stirred in the acid precipitation tank, thereby a waste water having pH of 3-4 was produced; meanwhile, terephthalic acid was produced; after the reaction of the acid liquid and the alkaline lysis solution was completed sufficiently, the waste water in the acid precipitation tank was introduced into a centrifugal filter so as to be filtered, such that terephthalic acid was separated therefrom; the waste water obtained by filtering via the centrifugal filter was finally introduced into a biochemistry processing system so as to meet the discharge standard. The grid was mainly used for intercepting the larger particle and other pollutants having a larger diameter in water, such as cotton yarn, cloth and other floating debris; the adjusting pool was used for buffering the amount of water, homogenizing the water, settling the larger solid particles, so as to facilitate the subsequent treatment processes. It was further noted that, the filtrate obtained by the centrifugal filter had a greatly reduced sewage COD, increased BOD5/COD value and increased biodegradability. The terephthalic acid separated by filtering and dehydration via the centrifugal filter was washed or not washed (as needed) and then stored in a package for transportation.

EXAMPLE 3

[0050] The method for preparing a high-count textiles comprises the following steps:

[0051] a. preparing an alkaline degradable slice: during the polymerization of polyester raw materials, 5-sodium sulfonate-isophthalate polyethylene glycol ester containing totally 3 wt % of polymers and isophthalate containing totally 4 wt % of polymers were added, the obtained mixture was stirred and heated to 230 C., so as to form a slurry; the obtained mixture was transformed into a reactor, meanwhile adding polyethylene glycol containing 3 wt % of polymers, so as to dilute and cool the mixture to 210 C.; sequentially polyethylene glycol having molecular weight of 6000 was added into the reactor for the period of 50 min under stirring, wherein the amount of polyethylene glycol was 2% of the total weight of the polymers; under atmosphere, the mixture was heated up to 230 C. such that the mixed raw materials were polymerized under vacuum; finally, the polymerized alkaline degradable slice successively was casted into a strip, cooled, pelletized, dried and screened, wherein the intrinsic viscosity of the alkaline degradable slice was 0.63;

[0052] b. preparing a blended spun melt: during the preparation of a spun melt, an easily hydrolysable substance was added into the spun melt so as to blend therein, wherein the weight ratio of the alkaline degradable slice to the easily hydrolysable substance was 85:15; during the alkaline dissolution and degradation, said easily hydrolysable substance was filtered partly or dissolved out, such that micropores were formed on the surface of a fiber;

[0053] c. preparing an easily alkaline soluble and degradable fiber by spinning, wherein the easily alkaline soluble and degradable fiber was a fiber strip; wherein a conventional spinning process was carried out at 285 C.; fiber fineness was 5.5tex/24F, fiber length was 38 mm, tensile strength was 2.2cn/dtex and break elongation was 24%; After spinning into the net and carding process, trips were made in term of the specifications of 20 g/m; the fiber strip was combined and mixed with a cotton strip, so as to form 100 s fine yarns. The ratio of the easily alkaline soluble and degradable fiber to the cotton is 20%:80%;

[0054] d. preparing a high-count yarn textile: the above blended yarn was woven to form gray cloth having plain weaves through a conventional weaving process, such as by using a circular knitting machine. In the overflow tank, during the pre-treatment process of the faber, 5 g/L of 100% NaOH was added at 110 C. for 60 min, and the other additions were the same as those used in the conventional pre-treatment process; the easily alkaline soluble and degradable fiber was dissolved. The later dyeing and the pro treatment process were the same as those for the above cotton yarn fiber. Finally, a high-count cotton fiber of 80 g/m2 was obtained.

[0055] As shown in FIG. 3, the step of recovering the solute in an alkaline lysis solution during the preparation of the high-count textiles was as below: the alkaline lysis solution obtained after the degradation of the easily alkaline soluble and degradable fiber was introduced through a grid into an adjusting pool, then the alkaline lysis solution in the adjusting pool was subjected to a pre-treatment and a film system; the alkaline lysis solution from the film system was introduced into an acid precipitation tank and an acid liquid was pumped into the acid precipitation tank by an acid adding pump; the acid liquid and the alkaline lysis solution were stirred in the acid precipitation tank, thereby a waste water having pH of 3-4 was produced; meanwhile, terephthalic acid was produced; after the reaction of the acid liquid and the alkaline lysis solution was completed sufficiently, the waste water in the acid precipitation tank was introduced into a centrifugal filter so as to be filtered, such that terephthalic acid was separated therefrom. The grid was mainly used for intercepting the larger particle and other pollutants having a larger diameter in water, such as cotton yarn, cloth and other floating debris; the adjusting pool was used for buffering the amount of water, homogenizing the water, settling the larger solid particles, so as to facilitate the subsequent treatment processes. It was further noted that, the filtrate obtained by the centrifugal filter had a greatly reduced sewage COD, increased BOD5/COD value and an increased biodegradability. The terephthalic acid separated by filtering and dehydration via the centrifugal filter was washed or not washed (as needed) and then stored in a package for transportation.

EXAMPLE 4

[0056] The differences of the example 4 from examples 1, 2 and 3 are that: the easily alkaline soluble and degradable fiber was made into a non-woven fiber, and the non-woven fiber was made into an embroidered cloth; the embroidered cloth was embroidered by using an embroidery thread, so as to form various patterns. Then the non-woven cloth embroidered with various patterns was immersed into an alkali solution, so as to dissolve the easily alkaline soluble and degradable fiber, thereby obtaining an embroidered article.

[0057] The above description is only for the preferred embodiment of the present invention. It would be apparent for those skilled in the art, various modifications can be made to according to the spirit of the present invention within the particular embodiments and application range of the present invention. The content of the present specification cannot be considered to limit the present invention.