Research and development of pure cotton fluffy yarn and products
1 Development of bulky yarn
The development of bulky yarn must first transform the forming mechanism of the existing ring spinning machine, design and test the corresponding sizing process, and select the appropriate weaving The reed density and heddle eyelet ensure good process performance of the fluffy yarn. Post-processing is the key to ensuring the fluffy performance. With appropriate process conditions, the main body of the fluffy yarn network is not deformed, and the super fluffy, especially soft, rich, light and comfortable special functions of pure cotton products can be fully displayed, making the Pure cotton products are presented to users with an unprecedented new look, adding vitality to the market.
Blending, twisting, and wrapping natural fibers such as cotton, wool, silk, and hemp with chemical fibers and synthetic fibers to change their functionality was the main direction in the 1980s and 1990s, but it has not yet Change the basic characteristics of its products. In the 21st century, twistless yarn products appeared among the products, which made a sensation among the looping products. Pure cotton towels use untwisted yarn, and the terry loops of the towels are extremely fluffy and soft. They are used for wiping the face and cleansing the body. They have an extremely soft feel and are known as beauty and skin care towels. However, this product is regarded as a beauty and skin care towel because of the twist that maintains the fiber cohesion. After being lifted, the yarn becomes parallel loose fibers, so it is as soft as cotton batting and loses its structural fastness. The lint rate is very high during the washing process, and the number of uses is greatly reduced. Therefore, it is only easy to use dry, which greatly reduces the untwisted quality. Application range of yarn products. Moreover, the loops are in the shape of loose fibers, and their elasticity is also lacking. The texture is more than soft but not fluffy enough.
The super fluffy yarn products designed by our company are spun on the spiral coupler designed and produced by Jiaxing University. The production of pure cotton super fluffy yarn products is a process technology independently developed by our company. The products have no twists. The feel of yarn is good, but it is not easy to shed. The proportion of pure cotton products is only 1/3 of the yarn count of pure cotton with the same structure. The fullness of elasticity has the effect of synthetic fiber fluffy yarn. It is a new product that has not yet appeared on the market and has advanced originality.
In view of the product’s special good applicability and extremely comfortable, soft, light, fluffy and elastic characteristics, fluffy yarn products will become the new favorite among textiles.
2 The yarn forming mechanism and process method of ring spinning pure cotton fluffy yarn
2.1 The yarn forming mechanism of spiral coupler
Spiral coupler It is a yarn-forming device installed on the FA 506 ring spinning machine. In addition to the inherent yarn-forming mechanisms such as draft rollers, aprons, and spindles of the spinning machine, a spiral clutch and core wires need to be installed on the cradle. Unwinding stand. The spinning core yarn is fed from behind the upper and lower front rollers, and is compositely spun with the roving sliver under the tension control of the spiral clutch. The yarn forming mechanism is the network covering process of roving cotton fiber and core wire. The twist generated by the spindle is transmitted by the jaws of the front roller. Under the action of the spiral clutch, the whiskers drawn out of the front roller change from flat to round. Shape, during which the fiber transfer phenomenon occurs when the slivers are formed into yarn, and the fibers with high tension tend to transfer to the inside of the yarn. The fibers with low tension are transferred outward, and the yarn is continuously formed into yarn due to the rotation of the spindle. This process causes the cotton fibers to form a network covering. Moreover, the fibers inside the yarn form a three-dimensional structure that is tight inside and loose outside due to the twisting effect, making the yarn fluffy and generating support stress for the network yarn, so its energy recovery is improved.
2.2 Analysis of the technology and process of preparing bulky composite yarn by ring spinning (see Figure 1)
2.2.1 The unwinding method of the core yarn:
The unwinding of the core yarn The winding method is very critical for spinning bulky yarn. If the core thread tension is unstable during the spinning process, the coating effect will be affected.
2.2.2 Arrangement of core wires
The spindle pitch of the ring spinning machine is 70 mm, and the overall arrangement of the original mechanism is very compact. The traditional spinning machine is modified so that it can spin fluffy composite yarn. Corresponding to each spindle, the participating core yarn packages must be reasonably discharged. The method is to place the core wire package on the top of the spinning machine, and use a sliding bearing to set it on the hollow shaft of the creel. The core wire is unwound in the radial direction under the action of unwinding tension.
The hollow structure is produced by two mechanisms: one is due to the flow of fibers inside the strand; the other is due to the fact that during the twisting process, the outer fibers at the edge of the strand are smaller than those in the center of the strand. The inner fibers are under greater tension.
Figure 1 Technical route of pure cotton bulky yarn
2.2.3 Pure cotton bulky yarn composite yarn processing technology
The core tensioner controls the tension of the core yarn. The guide wheel device controls the position of the core wire being fed into the short fiber twisting area to ensure that the core wire is always in the center of the twisting triangle area when the core wire and the short fiber are combined and twisted. The specific characteristics of this method are as follows.
1) On the two-zone three-roller drafting mechanism of the ring spinning machine, the short fiber sliver is still fed from the bell mouth and drafted by the cradle drafting mechanism, while the core wire is drawn from the holding The front roller nip feeds and merges with the drawn short fiber sliver:
2) When the core wire is fed into the short fiber sliver twisting area by the front roller, the core wire is fed by a precision-made guide The wheel transmits and controls it to accurately align with the center of the short fiber whiskers, and after converging with the short fiber whiskers, they jointly enter the twisting triangle area for compound twisting:
3) The core wire tension is controlled by a specific tension device. When the filament and short fiber strands are coaxially compound-twisted in the twisting triangle areaCotton towels can hold 230 ml more water; they can hold 300 ml of water in 60 seconds, which is 100 ml more than ordinary cotton towels.
5.2.4 Bulking (compression bulk) (Table 3)
<CENTER> A set of core yarn feeding device is installed on the machine, and the core yarn is input into the yarn drafting area for production. The spinning mill can produce fluffy yarn without increasing a large amount of investment. Moreover, this yarn has a fixed number of twists and can also be used to produce fluffy and untwisted yarn products. Another kind of fluffy yarn structure is the same as the structure of ring-spun fluffy yarn. The core wire is also covered into yarn, but the yarn is spun using a rotor, and the cotton fiber is networked around the core wire to form yarn. The hollow structure is stronger and the product is bulky. Better than ring spinning.
There is also a spinning method that creates a fluffy yarn effect, that is, blending soluble PVA with cotton fiber. The meridional distribution of ring spinning twist is that the outer layer has a large twist and the inner layer has a small twist. The difference in twist distribution on a yarn cross section, and the expansion and contraction produced when PVA dissolves, adjust the fiber stress of the yarn. The inner fiber has a small twist and a large space after the PVA is dissolved, which allows the cotton fiber to stretch elastically and transfer to the outside, resulting in hollowing. This bulky yarn ratio can be expanded to 37% to 40%. However, due to the reduced cohesion between fibers and low friction, the strength loss is large, and the hair removal rate increases after the product is formed. Therefore, when designing and producing fluffy yarn products, the weaving density must take into account the volume change of the fluffy yarn after the fibers are melted, and appropriately increase the weaving density so that the finished product has sufficient weaving strength and locks the fluffed fibers to reduce the hair removal rate.
The development of fluffy yarn has changed the texture of pure cotton fabrics. Yarns of the same count consume the same amount of fiber, but the products are thicker and softer. The product with the same organizational structure feels softer and more elastic. Its hygroscopicity, moisture retention, warmth retention, heat insulation and comfort are all better than those of conventional cotton yarn products, which greatly improves the quality of cotton fabrics. For this reason, the promotion and application of fluffy yarn will drive various textile products Develop more novel and comfortable new products, making a qualitative leap in daily necessities.
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