From function to aesthetics: the two-way empowerment journey of FDY full dull yarn series

FDY full dull yarn series basic concept

1. Definition and connotation

FDY, namely FULLY DRAWN YARN, is called fully drawn yarn in Chinese. By introducing the drawing effect in the spinning process, a winding yarn with high orientation and medium crystallinity can be obtained, which is the fully drawn yarn. On this basis, FDY full dull yarn series adds a high content (usually about 1%) of anatase titanium dioxide (TiO₂) to the sliced chemical fiber filament to eliminate the gloss of the fiber. This addition changes the reflection and refraction of light by the fiber, presenting a unique matte texture, which is different from the gloss effect of glossy and semi-dull yarns.

2. Comparison with other types of chemical fiber filaments

In terms of glossiness, shiny yarn (or large shiny yarn) does not contain TiO₂ in the slices. Its surface is smooth, and it reflects light strongly. It has a bright luster, often giving people a gorgeous and dazzling feeling. It is used in stage costumes and some high-end dress fabrics. It can reflect brilliant light under the light and create a strong visual effect. Semi-dull yarn contains 0.3% titanium dioxide, and its glossiness is at an intermediate level. It has a certain soft luster, which is neither too bright and dazzling, nor too dull. It is widely used in home textile bedding, daily shirts, dresses and other products to meet people's dual pursuit of beauty and practicality. FDY full dull yarn series achieves extremely low gloss with a titanium dioxide content of about 1%, presenting a completely matte effect.

In terms of performance characteristics, conventional chemical fiber filaments focus on basic strength, wear resistance, etc. In addition to the high strength and good wear resistance of chemical fiber filaments, FDY full dull yarn series also has excellent deep dyeing and hiding properties due to its unique matting treatment. The deep dyeing property allows it to absorb more dyes and present rich and full colors. It is particularly suitable for making dark products, such as classic black and dark blue clothing, or blackout curtains and other textiles that require high color depth. The hiding property can effectively cover the defects and uneven colors of the bottom layer of the fabric, making the finished fabric more uniform.

FDY full dull yarn production process

1. Raw material selection

The raw materials for FDY full dull yarn production are mainly polyester chips, and their quality directly affects the performance of the final product. High-quality polyester chips should have a stable molecular weight distribution, low impurity content and good spinnability. When selecting polyester chips for the production of full dull yarn, it is necessary to focus on its compatibility with titanium dioxide to ensure that titanium dioxide can be evenly dispersed in the polyester matrix during subsequent processing to achieve a stable and ideal dulling effect.

For titanium dioxide, anatase titanium dioxide is usually selected as a dulling agent. The crystal structure of anatase titanium dioxide enables it to effectively scatter light in polyester fibers, thereby achieving the purpose of dulling. Its particle size and distribution have a significant impact on the dulling effect and fiber performance. The appropriate titanium dioxide particle size is between 0.2 and 0.5 microns. If the particle size is too small, the dulling effect may not be obvious; if the particle size is too large, it is easy to form defects inside the fiber and reduce the fiber strength.

2. Detailed explanation of production process

The production process of FDY full dull yarn is relatively complicated, mainly including key links such as chip drying, melt extrusion, spinning, stretching, and winding. Chip drying is the first step in production. Since polyester chips absorb a certain amount of water during storage and transportation, if the moisture content is too high, it will cause polyester hydrolysis during the high-temperature melting stage, reduce the molecular weight, and affect the fiber quality. Special drying equipment is required to reduce the moisture content in the chips to below 50ppm. In the melt extrusion stage, the dried polyester chips are transported to the screw extruder. Driven by the screw, the chips gradually heat up to above the melting point in the barrel to achieve complete melting. Titanium dioxide masterbatch is accurately measured and added according to the formula, and is evenly dispersed in the molten polyester melt through the stirring and mixing of the screw. Spinning is the process of extruding the molten polyester melt through the spinneret to form a filament. There are many precisely machined small holes on the spinneret, and their hole diameter, shape and arrangement determine the cross-sectional shape and fineness of the filament. After the melt is extruded from the spinneret, it exchanges heat with the cooling air in the spinning tunnel, and quickly cools and solidifies to form nascent fibers. The stretching process gives the fiber a certain degree of orientation and strength. The nascent fiber is guided by the guide wire disc and enters the stretching device, where it is stretched in multiple stages in different temperature zones. By controlling parameters such as the stretching multiple, stretching temperature, and stretching speed, the fiber molecular chains are oriented along the fiber axis, thereby improving the fiber's strength, modulus, and other performance indicators. Winding is to wind the stretched fiber on the bobbin according to a certain rule to form a FDY full dull yarn finished package. During the winding process, the winding tension must be stable to ensure the molding quality of the package and avoid defects such as collapsed edges and convex shoulders.

3. Key technical difficulties and solutions

In the production process of FDY full dull yarn, the uniform dispersion of titanium dioxide is a key technical difficulty. If titanium dioxide is unevenly dispersed, it will lead to inconsistent fiber matting effects, appearance defects such as gloss spots, and will also affect the uniformity of fiber strength. To solve this problem, on the one hand, optimization is carried out on the production equipment, such as using high-performance screw mixing elements to enhance the mixing effect of the melt during the extrusion process; on the other hand, the titanium dioxide masterbatch is pretreated to improve its surface activity and improve its compatibility with the polyester melt.

Another difficulty lies in the static electricity problem in the production process. Since FDY full dull yarn rubs against equipment components at high speed during spinning and stretching, static electricity is easily accumulated. Static electricity not only absorbs dust and affects the appearance quality of the fiber, but also may cause the yarn to flutter and entangle, affecting the stability of production. It is usually adopted to install static electricity elimination devices in the production environment, such as ion wind rods, etc., to neutralize static electricity on the fiber surface; add antistatic agents to the oil formulation to reduce the surface resistance of the fiber and accelerate static electricity leakage.

FDY full dull yarn performance advantages

1. Optical properties

The most outstanding optical property of FDY full dull yarn is its excellent matte effect. Due to the addition of a high proportion of anatase titanium dioxide, light is scattered and absorbed multiple times inside the fiber, and it is almost impossible to form a mirror reflection, thus presenting a uniform matte appearance. This unique matte effect gives it a low-key and luxurious visual sense, which is in sharp contrast to the bright luster of glossy silk. In practical applications, in the field of high-end clothing, some internationally renowned luxury brands often use FDY full dull yarn fabrics to make high-end custom clothing, such as coats and evening dresses in the autumn and winter series. Its matte texture can better show the tailoring and texture of clothing, creating a restrained and elegant temperament. In the field of home textiles, when used to make high-end curtains, it can effectively avoid glare caused by light reflection, adding a soft and comfortable atmosphere to the interior space.

2. Mechanical properties

In terms of strength, FDY full dull yarn has a high tensile strength. During the production process, the fiber molecular chains are highly oriented by precisely controlling the spinning and stretching process parameters, giving the fiber good mechanical properties. Its breaking strength can meet the use requirements of most textiles. Outdoor sunshade products such as parasols and awnings made of FDY full dull yarn can maintain good shape and structural stability under long-term exposure to wind and sun, and are not easy to break or damage due to its high strength. FDY full dull yarn also has excellent wear resistance. Its surface is relatively smooth and the fiber structure is tight. When rubbed, it is not easy to produce pilling and pilling. This feature enables the clothing and home textile products made of it to maintain good appearance and performance during daily use and washing, and extend the service life. It is used in some workwear and denim clothing to effectively cope with friction in the working environment and wear and tear from daily wear and washing.

3. Chemical stability

FDY full dull yarn has good chemical stability. The chemical properties of polyester fiber itself are relatively stable and it is not easy to react with common chemicals. The titanium dioxide added during the production process will not have a negative impact on the chemical stability of the fiber. It is resistant to bleach, oxidants, hydrocarbons, ketones, petroleum products and inorganic acids, and to a certain extent, it is also resistant to dilute alkali and is not afraid of mold. This chemical stability allows FDY full dull yarn to maintain stable performance in various complex environments. In the field of industrial filtration, when used to make filter cloth, it can resist the erosion of chemical substances in the filter medium and ensure the long-term stability of the filtration effect.

4. Dyeing performance

FDY full dull yarn has significant advantages in dyeing performance, and its deep dyeing performance is outstanding. Due to the internal structure of the fiber and the presence of titanium dioxide, the fiber's adsorption capacity for dyes is enhanced, and it can absorb more dyes, thus presenting rich and full colors. Compared with ordinary chemical fiber filaments, under the same dyeing conditions, FDY full dull yarn can dye deeper and brighter colors. In the textile printing and dyeing industry, for some dark products such as black, dark blue, dark purple, etc., FDY full dull yarn is an ideal choice. This meets consumers' pursuit of fashionable colors and provides designers with a broader creative space to design colorful and layered textiles.

FDY full dull yarn application areas

1. Clothing field

High-end fashion clothing: In the field of high-end fashion clothing, FDY full dull yarn has become the favorite choice of many well-known designers due to its unique matte texture, excellent dyeing performance and good drape. In high-end custom dresses, its low-key and luxurious appearance can perfectly set off the wearer's temperament and show a unique and elegant taste. The autumn and winter series coats of some internationally renowned luxury brands use FDY full dull yarn fabrics. After exquisite tailoring and process treatment, they not only have excellent warmth retention performance, but also give people a sense of calmness and atmosphere visually. In terms of fashion and trendy clothing, with the pursuit of personalized and high-quality clothing by consumers, FDY full dull yarn has gradually emerged. Some designers use it in clothing items with unique design styles, such as irregularly cut dresses, personalized tops, etc., and combine its special texture with design to create clothing styles that lead the fashion trend.

Functional clothing: In the field of sportswear, FDY full dull yarn is also widely used. Its good moisture absorption and perspiration wicking performance can quickly absorb human sweat and discharge it to the surface of the fabric, keeping the wearer dry and comfortable. Some high-end sports brands' professional sportswear use functional fabrics containing FDY full matte yarn. While meeting the functional needs of athletes for clothing, its matte appearance also adds a sense of fashion to sportswear. In terms of outdoor clothing, the weather resistance and wear resistance of FDY full matte yarn play an important role. When making outdoor windbreakers, assault jackets and other products, it can resist the erosion of harsh outdoor environments, such as ultraviolet radiation, wind and sand friction, etc. At the same time, its strong dyeability makes outdoor clothing more colorful and diverse, meeting consumers' dual requirements for clothing functionality and aesthetics during outdoor activities.

2. Home textile field

Curtains: In home textile curtain products, FDY full matte yarn has many advantages. Its excellent light-shielding performance can effectively block direct sunlight and create a comfortable light environment for the room. It is especially suitable for bedrooms, study rooms and other spaces with high light requirements. With deep dyeing, the curtains are rich in color and durable, which can meet the matching needs of different home styles. Whether it is simple modern style, European classical style or Chinese style, you can find FDY full dull yarn curtains that match it.

Bedding: The application of FDY full dull yarn in bedding sets and other bedding can bring consumers a comfortable sleeping experience. Its soft touch fits human skin and reduces discomfort during sleep. The moderate glossiness creates a warm and comfortable atmosphere under the bedroom light. Moreover, its good wear resistance and color fastness enable the bedding to maintain good appearance and performance after long-term use and washing.

3. Industrial textiles field

Industrial filtration: In the field of industrial filtration, such as liquid and gas filtration in chemical, pharmaceutical, food and other industries, filter cloth made of FDY full dull yarn plays an important role. Its chemical stability enables it to resist the erosion of various chemical substances in the filter medium, ensuring the long-term stability of the filtration effect. The higher strength and wear resistance make it not easy to be damaged when it is subjected to pressure and friction during the filtration process, extending the service life of the filter cloth.

Automotive interior: In terms of automotive interior, FDY full matte yarn can be used to make automotive seat fabrics, interior decorative fabrics, etc. Its good wear resistance can cope with the friction during daily riding and use, and it is not easy to pilling, so as to maintain the beauty of the interior. It has strong dyeability and can be dyed to a color that matches the overall interior style of the car, thus improving the texture and comfort of the interior space.

Keeping FDY full dull yarn in the best condition: maintenance and troubleshooting tips

1. Core characteristics of FDY full dull yarn and "best condition" standard

To keep it in the best condition, key indicators must be clarified first:

Physical properties: breaking strength ≥3.0cN/dtex, elongation at break 15%-25%, yarn uniformity (CV value) ≤1.5%, no obvious hair or broken ends.

Appearance quality: uniform matte (titanium dioxide particles are well dispersed), no oil stains, color spots, stiff yarns, and flat package forming (no collapsed edges or convex shoulders).

Stability: During storage and processing, performance fluctuations are small and dyeing uniformity is good.

2. Full process maintenance tips

(1) Maintenance during production (source control)

Raw material and spinning parameter control

Chip quality: Ensure that the polyester chips are of high purity and moisture content ≤30ppm to avoid impurities clogging the spinneret holes.

Spinning temperature: According to the characteristics of the slice, it is stable at 280-290℃, and the temperature fluctuation is ≤±1℃ to prevent uneven thickness of the filaments due to uneven temperature.

Cooling conditions: The side wind speed (0.3-0.6m/s) and wind temperature (20-25℃) are stable to ensure uniform cooling of the filaments and reduce internal stress.

Stretching multiple: According to the requirements of the finished product, it is controlled at 3.5-4.5 times, and the temperature of the stretching roller (80-120℃) is uniform to avoid excessive stretching and causing hair.

Winding and maintenance

Winding speed: Maintained at 3000-4000m/min, speed fluctuation ≤±5m/min, to prevent uneven tightness of the package.

Tension control: The winding tension is stable at 0.5-1.0cN/dtex. Excessive tension fluctuations can easily lead to broken ends or deformation of the package.

Equipment cleaning: Clean the spinneret (clean with triethylene glycol), yarn guide, and winding machine rollers daily to avoid dirt accumulation that may cause scratches on the yarn.

(2) Storage and transportation maintenance

Storage environment

Temperature and humidity: Temperature 20-30℃, relative humidity 50%-60%, avoid moisture that may cause the yarn to absorb moisture and become sticky (especially in high humidity areas, a dehumidifier should be installed).

Stacking requirements: The rolls should be placed upright, with a stacking height of ≤5 layers to avoid deformation of the rolls due to heavy pressure; the distance from the ground should be ≥30cm, and away from the wall (to prevent moisture).

Pollution prevention: Keep the storage area clean to avoid dust and oil from contacting the yarn; do not place it with volatile chemicals (such as formaldehyde and acetone) to prevent chemical corrosion.

Transportation precautions

Avoid severe vibration: Fix the rolls during transportation to prevent collisions that may cause the rolls to loosen or the yarn to break.

Sun and rain protection: The transportation vehicle must be sealed to avoid direct sunlight (to prevent yarn aging) and rain.

(3) Maintenance during post-processing (before weaving/dyeing)

Unwinding stage

Unwinding tension: Adjust according to the type of equipment. Too much tension will cause the yarn to break easily, while too little tension will cause the yarn to become tangled easily.

Wire guide path: Ensure that the wire guide is smooth and free of burrs. Regularly check and replace worn parts to avoid friction between the yarns and the generation of hair.

Pretreatment cleaning

Before weaving, the yarn surface oil residue can be removed by washing with hot water (60-80℃) to avoid oil stains affecting dyeing uniformity.

3.Common abnormalities and troubleshooting techniques

(1) Appearance abnormalities

(2) Performance-related abnormalities

Insufficient breaking strength/abnormal elongation

Reasons: Insufficient stretching multiple (low strength, high elongation) or excessive stretching (slightly higher strength but sudden drop in elongation), wide molecular weight distribution of chips.

Troubleshooting: Recalibrate the stretching multiple (adjust ±0.2 times according to test data); replace chips with narrow molecular weight distribution.

Uneven matting (local bright spots)

Reasons: Poor dispersion of titanium dioxide in the chips and uneven melt mixing during spinning.

Troubleshooting: Check the chip mixing equipment (such as static mixer) to ensure that the matting agent is evenly dispersed; add dispersant (such as zinc stearate) if necessary.

Uneven dyeing (color flowers)

Reasons: Excessive residue of silk thread oil, large difference in crystallinity, and uneven tension during dyeing.

Troubleshooting: Increase the pretreatment hot water washing time (extend 5-10 minutes); adjust the spinning cooling conditions to reduce crystallinity fluctuations; keep the tension stable during dyeing.

(3) End breakage during processing

High frequency end breakage: Prioritize checking the wire guide path (whether there are scratches), unwinding tension (whether it is too high), and package forming (whether there is edge collapse resulting in uneven force on the wire strips).

Periodic end breakage: Mostly caused by eccentricity of the winding machine roller or bearing wear, the equipment needs to be repaired and the worn parts replaced.

Why YUWEI FDY full dull yarn series is the right choice for your project

Unique appearance effect: Full dull yarn can completely eliminate the fiber luster by adding a higher content of dulling agent, presenting a soft matte texture, which is closer to the texture of natural fibers such as cotton and wool. This matte effect can make the product have a low-key and stable style, which is suitable for high-end clothing, home textiles and other projects that pursue natural texture. It also has good hiding power, which can effectively cover the defects and uneven colors of the bottom layer of the fabric, making the finished fabric more uniform and consistent.

Good mechanical properties: Full dull yarn is strong and powerful, not easy to break, and has a certain elasticity and shrinkage, which makes the textile products have good reliability and wrinkle resistance.

Good heat resistance: As a thermoplastic fiber, it can maintain a stable shape at high temperature, which is suitable for making textiles such as pleated skirts that require long-lasting pleats.

Strong corrosion resistance: It can resist the erosion of a variety of chemicals, including bleach, oxidants, hydrocarbons, ketones, petroleum products and inorganic acids, which can extend the service life of the product.

High color fastness: There is no specific dyeing group on the polyester molecular chain, and it is not easy to fade after washing after dyeing. The color fastness is good, which helps to keep the product bright for a long time.

Good hygroscopicity and breathability: There is no stuffiness when wearing, it is not easy to carry static electricity and stain dust, it is beautiful and comfortable, helps to regulate body temperature, and is suitable for making underwear and sportswear.

Wide range of application fields: FDY full dull yarn series can be widely used in clothing, home textiles and other fields. In terms of clothing, it is a high-quality material for making sportswear, underwear, casual wear, children's wear, etc. In the field of home textiles, it can be used for the production of products such as curtains and sofa covers, which can meet the needs of different projects. At the same time, because of its anti-ultraviolet characteristics, it can also be used in the production of functional products such as sunscreen clothing and agricultural sunshade films.

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