What are the technical difficulties in the production of polyester embossed fabrics?

The technical difficulties in the production of polyester embossed fabrics are mainly reflected in the following aspects:

Raw material selection and processing
Polyester fiber quality control: The quality of polyester fiber directly affects the performance of the fabric. To produce high-quality polyester embossed fabrics, it is necessary to strictly control the molecular weight distribution, crystallinity, impurity content and other indicators of polyester fiber. If the molecular weight distribution is uneven, the strength of the fabric may be inconsistent; too high or too low crystallinity will affect the softness and elasticity of the fabric.
Fiber pretreatment difficulty: In order to make the polyester fiber better accept the embossing treatment, pretreatment is required, such as oil removal, impurity removal, hydrophilic modification, etc. Improper treatment will result in poor fiber surface performance, affect the embossing effect, and cause unclear and weak patterns.

Embossed process control
Temperature and pressure balance: In the embossing process, temperature and pressure are key factors. If the temperature is too low, the embossing mold cannot produce enough plastic deformation of the polyester fabric, and the pattern is difficult to form; if the temperature is too high, the fabric may melt, discolor or even be damaged. If the pressure is too low, the pattern is unclear; if the pressure is too high, the fabric thickness may be uneven, or even piercing may occur.
Embossing speed control: Embossing speed is related to temperature and pressure. If the speed is too fast, the fabric stays in the embossing mold for too short a time and cannot be fully formed; if the speed is too slow, it will affect production efficiency and may also cause local overheating of the fabric.
Mold design and manufacturing: High-quality embossing molds are the basis for achieving exquisite patterns. The precision, hardness, surface finish, etc. of the mold are very high. The mold design needs to consider factors such as the complexity, depth, and angle of the pattern. Any slight deviation in the manufacturing process may affect the embossing effect. Moreover, the mold may also wear and deform after long-term use, and regular maintenance and replacement are required.

Post-processing technology
Dyeing uniformity: When dyeing embossed polyester fabrics, uneven dyeing is prone to occur due to differences in fiber structure and surface properties between the embossed and unembossed parts. The embossed area may have a stronger or weaker adsorption capacity for the dye, resulting in different shades of color.
Matching of finishing process: Finishing processes such as soft finishing and anti-wrinkle finishing need to be matched with embossing processes. Different finishing agents may affect the embossing effect. For example, some finishing agents may blur the embossed pattern or affect the feel and appearance of the fabric.
Quality stability: Ensuring that the post-treated fabric maintains the stability of the embossing effect and overall quality under different environmental conditions (such as temperature and humidity changes) is also one of the difficulties. The fabric may have problems such as embossed pattern rebound, fading, shrinkage, etc., which affect the performance and aesthetics of the product.
Environmental protection and sustainable development requirements
Wastewater treatment: In the production process of polyester embossed fabrics, dyeing, finishing and other links will generate a large amount of wastewater, which contains pollutants such as dyes and auxiliaries. To achieve the standard discharge of wastewater, advanced sewage treatment technology and equipment are required to remove pollutants such as chromaticity and chemical oxygen demand (COD) in the wastewater, which increases the technical difficulty and cost of production.
Energy consumption and emission reduction: While pursuing production efficiency and quality, reducing energy consumption and greenhouse gas emissions is a challenge facing the industry. Enterprises need to develop and apply energy-saving production equipment and processes and optimize production processes to reduce the impact on the environment.