High-coverage, low-hairiness, self-reinforcing structural composite yarns based on a novel spreading apparatus in the ring machine

Abstract

Composite ring spinning, an advanced physical method, is extensively used for preparing required yarns because of its structural architecture. However, the existing staple fiber/filament composite ring-spun yarns involve more hairiness, lower coverage, and weaker tensile strength, limiting further development. Herein, we proposed a novel specialized multifilament-spreading apparatus to fabricate high-coverage, low-hairiness, and self-reinforcing structural composite yarns. The key idea is to realize the cylindrical-shaped multifilament into a quasi-single layer (q-SL) form by using a herringbone-groove spreading roller (HGSR). After that, the q-SL is twisted with the traditional staple fibers, and finally the multifilament spread composite-structural yarn (FS-CSY) can be controllably prepared. To verify the practicality and feasibility of the proposed spinning method, the FS-CSY and the common bi-component composite yarn (b-CY) were systematically compared and analyzed. The results indicate that the FS-CSY shows a uniform q-SL wrapping structure on cotton fibers with the coverage rate of 61.98% compared with that of b-CY. Furthermore, the q-SL wrapping structure results in a lower hairiness (20.9 units) and higher cover probability (32.98%) than that of b-CY, representing excellent surface and evenness of the as-prepared FS-CSY. In addition, comparing FS-CSY and b-CY, the FS-CSY had a better self-reinforcement, with an enhanced braking tenacity (21.27% higher) and initial modulus (45.05% higher). This fundamental work represents an important step towards the large-scale production of FS-CSY and an attempt to improve the comprehensive quality of ring-spun yarns.